GB/T 37563-2019 PDF English
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Safety requirements for pressurized water electrolysis system for hydrogen production
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GB/T 37563-2019: PDF in English (GBT 37563-2019) GB/T 37563-2019
GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 27.180
F 19
Safety Requirements for Pressurized Water
Electrolysis System for Hydrogen Production
ISSUED ON: JUNE 4, 2019
IMPLEMENTED ON: OCTOBER 1, 2019
Issued by: State Administration for Market Regulation;
Standardization Administration of the People’s Republic of
China.
Table of Contents
Foreword ... 3
1 Scope ... 4
2 Normative References ... 4
3 Terms and Definitions ... 5
4 Hazardous and Harmful Factors of Hydrogen Production System ... 6
5 Basic Requirements ... 9
6 Environmental Conditions ... 9
7 Equipment and Pipelines ... 10
8 Electrical and Instrument Control ... 13
9 Operation and Maintenance ... 16
10 Operating Personnel ... 19
11 Emergency Treatment ... 19
Appendix A (informative) A Block Diagram of Typical Hydrogen Production
System ... 21
Appendix B (informative) Hazardous and Harmful Factors of Main Hazardous
Chemicals and Unit Equipment of Hydrogen Production System ... 22
Bibliography ... 24
Safety Requirements for Pressurized Water
Electrolysis System for Hydrogen Production
1 Scope
This Standard specifies the hazardous and harmful factors, and basic safety
requirements of pressurized water electrolysis system for hydrogen production
(hereinafter referred to as hydrogen production system), as well as the requirements
for environmental conditions, system components, operation and maintenance,
operating personnel and emergency treatment.
This Standard is applicable to alkaline water electrolysis system and proton exchange
membrane water electrolysis system with an operating pressure greater than or equal
to 0.3 MPa, and less than or equal to 5.0 MPa.
NOTE: in this Standard, pressure refers to gauge pressure.
2 Normative References
The following documents are indispensable to the application of this document. In
terms of references with a specified date, only versions with a specified date are
applicable to this document. In terms of references without a specified date, the latest
version (including all the modifications) is applicable to this document.
GB/T 150 (all parts) Pressure Vessels
GB/T 151 Heat Exchanger
GB 2894 Safety Signs and Guideline for the Use
GB 3836.1 Explosive Atmospheres - Part 1: Equipment - General Requirements
GB/T 4272 General Principles for Thermal Insulation Technique of Equipment and
Pipes
GB 7231 Basic Identification Colors and Code Indications and Safety Sign for Industrial
Pipelines
GB 12014 Protective Clothing - Static Protective Clothing
GB 12358 Gas Monitors and Alarms for Workplace - General Technical Requirements
GB 16808 Combustible Gas Alarm Control Units
3.3 Risk Assessment
Risk assessment includes the whole process of risk identification, risk analysis and risk
evaluation.
3.4 Oxygen-enriched Atmosphere
Oxygen-enriched atmosphere refers to the environment where the volume fraction of
oxygen in the air is greater than 23.5%.
3.5 Hot Work
Hot work refers to unconventional work that might generate flames, sparks or hot
surfaces in the forbidden area beyond the process equipment that directly or indirectly
generates open flames.
NOTE: for example, the use of electric welding, gas welding (cutting), blowtorch, electric
drill and grinding wheel, etc.
4 Hazardous and Harmful Factors of Hydrogen
Production System
4.1 Hazardous and Harmful Factors of Composition and Unit Equipment
of Hydrogen Production System
The composition of the hydrogen production system is determined by factors, such as:
the purpose and purity of the produced hydrogen / oxygen. A block diagram of typical
hydrogen production system is shown in Appendix A.
The hazardous and harmful factors of the main hazardous chemicals and unit
equipment of the hydrogen production system are shown in Appendix B.
4.2 Leakage
Hydrogen would easily leak through porous materials, assembly surfaces or sealing
surfaces. After hydrogen leaks, it will rapidly diffuse, leading to continuous expansion
of the leakage-contaminated area, and the diffusion process is invisible to the naked
eye.
The electrolyte of the alkaline water electrolysis system might leak due to various
reasons.
4.3 Fire Disasters and Explosions
The condition that causes hydrogen to catch fire or to explode is that the mixture of
hydrogen and air or oxygen reaches the flammable or explosive limit, and there is an
k) The electrical equipment generates electric arcs or sparks due to electric
leakage, short circuit, overload and excessive contact resistance; the
explosion-proof level of electrical equipment in the hazardous area does not
meet the requirements for use, which might also become a source of ignition;
l) Raindrops or other conductive objects fall on the water electrolyzer, causing
a short circuit and damage to the tank body, which might cause fire disasters
or explosions;
m) During the maintenance process, no effective isolation measures are taken
between the troubleshooting equipment and the in-use production system; the
replacement before hot work is not thorough; the sampling and analysis are
unrepresentative, or the analysis data is inaccurate, which might cause fire
disasters or explosions.
4.4 Suffocation
Hydrogen is a simple suffocating gas. At its high concentration, the oxygen partial
pressure in the air decreases and causes hypoxic suffocation.
4.5 Electric Shock
In the hydrogen production system, equipment or facilities that might cause personal
electric shocks include: water electrolyzers, rectifier transformers, rectifier cabinets,
electrical cabinets, motors and power transmission copper bars, etc. During the
operation and maintenance of the equipment, there is a danger of electric shock for
the operating personnel.
4.6 Thermal Injury
In the hydrogen generation system, the operating temperature range of the water
electrolyzer and some of its auxiliary equipment is 60 °C ~ 90 °C. The operating
temperature of the deoxygenation catalyst bed of the hydrogen purifier may reach
150 °C; the regeneration temperature of the drying bed (temperature-swing adsorption)
of the hydrogen purifier may reach 350 °C; if human body directly contacts the surface
of the equipment, it will lead to thermal injury.
The potassium hydroxide or sodium hydroxide involved in the alkaline water
electrolysis system is highly corrosive; direct contact with the skin and eyes may cause
chemical burns.
4.7 Mechanical Injury
Mechanical Injury of the hydrogen production system mainly refers to the injury caused
by the direct contact of the moving parts of the mechanical equipment with the human
body.
kept unblocked.
6.2.4 Areas with alkaline liquor, including areas near the loading and unloading,
storage, analysis and sampling points of alkaline electrolyte, shall be equipped with
rinsing and eyewash facilities, and boric aqueous solution with a concentration of 2%
~ 3%.
6.2.5 The hydrogen production site should set up emergency lightings.
6.2.6 The hydrogen production site shall set up safety signs that comply with the
stipulations of GB 2894.
7 Equipment and Pipelines
7.1 General Requirements
7.1.1 The design, manufacturing, installation and acceptance inspection of the oxygen
recovery equipment, pipelines and accessories of the hydrogen production system
shall comply with the stipulations of GB 50177 and GB/T 19774.
7.1.2 In terms of hydrogen production systems where oxygen is directly discharged
into the equipment enclosure or indoors, the oxygen shall be effectively diluted by the
ventilation airflow, so as to avoid the formation of an oxygen-enriched atmosphere.
7.1.3 The selection of equipment and pipeline materials shall comprehensively
consider factors, such as: service conditions (such as: medium characteristics,
operating temperature and operating pressure, etc.), material properties (mechanical
properties, process properties, physical properties and chemical properties),
equipment manufacturing processes and economic rationality, etc.
7.1.4 The arrangement of equipment and pipelines shall make it convenient for
operation and maintenance; in case of an emergency, it shall be convenient for the
evacuation of personnel.
7.1.5 The condensed water in the hydrogen equipment and pipelines shall be drained
to the outdoors through the drainage water seal.
7.1.6 Preventive measures shall be taken for the stress and displacement caused by
expansion and contraction of the equipment and pipelines.
7.1.7 The degreasing of equipment, pipelines and their valves and accessories in
contact with oxygen shall comply with the stipulations of GB 50030 and HG 20202.
7.1.8 In accordance with environmental conditions and process requirements, the
thermal insulation measures taken for the equipment and pipelines shall comply with
the stipulations of GB/T 4272.
medium shall be applicable to alkaline liquor / pure water. If it is installed in a hazardous
area, it shall comply with the stipulations of 8.1.2.
7.2.5 Shut-off valve / cut-off valve
Shut-off valve / cut-off valve shall comply with the stipulations of GB 50177 and GB/T
19774. If the electric valve is installed in a hazardous area, it shall comply with the
stipulations of 8.1.2.
7.2.6 Pressure relief device
Safety valve shall be a fully-enclosed type. It may only be used after being lead-sealed
with qualification in calibration. The safety valve shall be vertically installed near the
equipment being protected; the installation location shall make it convenient for
inspection and maintenance.
7.2.7 Flame arrester
The hydrogen vent pipeline shall be equipped with a flame arrester. The setting of the
flame arrester shall comply with the relevant stipulations of GB 50177.
7.3 Pipelines and Accessories
7.3.1 The design and installation of pipelines and accessories of the hydrogen
production system shall comply with the relevant stipulations of GB/T 19774.
7.3.2 The hydrogen production system shall be equipped with nitrogen purging and
replacement ports. Cut-off valves and check valves shall be allocated before all the
nitrogen purging and replacement ports.
7.3.3 When hydrogen pipelines are co-supported with other pipelines, or laid in layers
with other pipelines, they should be arranged on the outer upper layer.
7.3.4 The supporting and hanging brackets of the hydrogen / oxygen pipelines shall be
made of non-combustible materials.
7.3.5 After the installation of the hydrogen / oxygen pipelines, strength test, air-
tightness test and leakage test shall be conducted. This type of tests shall be
performed in accordance with GB 50177 and GB 50030.
7.3.6 The purging of the hydrogen / oxygen pipelines that are qualified in the leakage
test shall comply with the relevant stipulations of GB 50177 and GB 50030. When using
nitrogen for purging, measures shall be taken to prevent from suffocation.
7.3.7 The hydrogen / oxygen vent pipes shall be within the lightning protection range.
In addition, there shall be measures to prevent from the intrusion of rains and snows,
and the blockage by debris.
8 Electrical and Instrument Control
8.1 General Requirements
8.1.1 The classification of the hazardous area of the hydrogen production system shall
comply with the stipulations of GB 50177 and GB 50058.
8.1.2 The electrical equipment in the hazardous area shall be selected in accordance
with the stipulations of GB 50058; the general requirements shall comply with the
stipulations of GB 3836.1. The explosion-proof grade shall not be lower than the grade
and group of hydrogen explosive mixtures.
8.1.3 The laying of cables and wires in a hazardous area shall comply with the
stipulations of GB 50217.
8.1.4 Anti-shock isolation facilities shall be added and installed around the water
electrolyzer and its power transmission copper bars.
8.1.5 There shall be safety measures to prevent the electric conductor from falling on
the water electrolyzer.
8.2 DC Power Supply
8.2.1 Each water electrolyzer shall be separately equipped with a DC power supply;
high-frequency switch rectifier, thyristor rectifier or diode rectifier should be adopted.
8.2.2 The DC power supply shall have the functions of voltage regulation and
automatic current stabilization; it shall be equipped with an overcurrent protection
device, which will automatically stop when it exceeds a predetermined value.
8.2.3 The high-voltage rectifier transformer equipped with the DC power supply shall
be located in a separate transformer chamber.
8.2.4 An emergency power-off button of the DC power supply shall be installed in the
electrolysis room. This button should be located in a place that is convenient for
operation.
8.3 Electro-heating Elements
8.3.1 The technical requirements of metallic tube-type electro-heating elements shall
comply with the stipulations of JB/T 2379.
8.3.2 In accordance with the operating temperature of the metallic tube-type electro-
heating elements, the insulation filling material between the heating wire and the
metallic tube shell shall be selected. The insulation resistance of the electro-heating
elements shall comply with the manufacturer’s stipulations.
8.3.3 For electro-heating elements in the pressure medium, measures shall be taken
to avoid accidents triggered by damage.
8.3.4 The electro-heating elements of the hydrogen purifier shall comply with the
stipulations of 8.1.2.
8.4 Grounding
8.4.1 The metal shell, metal pipeline, metal base or frame of the hydrogen production
system shall be grounded. The grounding shall comply with the stipulations of GB
50177 and GB 50057.
8.4.2 The connections of the hydrogen / oxygen equipment, pipeline valves and
flanges shall be connected by metal wires; the jumper resistance shall be less than
0.03 .
8.4.3 Before being connected to the pipeline, the water electrolyzer shall be checked
for grounding resistance in accordance with the structural characteristics. For water
electrolyzers respectively connected to the positive and negative poles of the DC
power supply at both ends, the resistance to ground shall be not less than 1.0 M.
8.4.4 The grounding of electrical installations shall be connected to the grounding trunk
through a separate grounding wire; no series connection is allowed.
8.4.5 All lightning protection and static protection grounding devices shall be regularly
tested for the grounding resistance at least once a year.
8.5 Hydrogen Leakage Detection
8.5.1 The hydrogen production system shall be equipped with a fixed hydrogen
detection alarm, and its technical performance shall comply with the stipulations of GB
12358 and GB 16808. The detector of the fixed hydrogen detection alarm shall be
installed in a place where hydrogen is easy to leak and accumulate.
8.5.2 The hydrogen production system shall be equipped with a portable hydrogen
detection alarm.
8.5.3 The fixed hydrogen detection alarm and the portable hydrogen detection alarm
shall be regularly calibrated.
8.5.4 The hydrogen detection alarm shall normally work during equipment
maintenance.
8.5.5 When the hydrogen content in the air reaches 0.4% (volume fraction), the
hydrogen detection alarm shall give an alarm, and simultaneously, actuate the
corresponding accident exhaust fan; when the hydrogen content in the air exceeds 1%
(volume fraction), stop and check.
8.6 Hydrogen Flame Detection
The hydrogen flame detection alarm shall be selected in accordance with the response
time, detection range, coverage, sensitivity and other factors, and comply with the
stipulations of 8.1.2.
8.7 Automatic Control System
8.7.1 The automatic control system of the hydrogen production system shall conduct
centralized monitoring and automatic adjustment of the main process parameters.
When the equipment fails, it shall promptly give an alarm, shut down the machine, and
properly handle it.
8.7.2 The measuring range and accuracy grade of the meter shall satisfy the
requirements for use. The meters in contact with oxygen shall be grease-free.
8.7.3 The outlet end of the water electrolyzer shall be equipped with an online content
analyzer for hydrogen in oxygen and oxygen in hydrogen to monitor the gas purity in
real time. The outlet of the hydrogen purifier shall be equipped with an analysis
instrument for impurity content in hydrogen.
8.7.4 The automatic control system should have (but are not limited to) the following
alarm or interlocking shutdown functions:
---High system pressure;
---High oxygen pressure;
---High / low differential pressure on both sides of hydrogen and oxygen;
---High temperature of water electrolyzer;
---High / low level of alkaline liquor / pure water;
---Low flow of alkaline liquor / pure water;
---DC overcurrent / DC power failure;
---DC power emergency switch-off button takes action / external emergency stop
signal;
---High hydrogen content in general oxygen;
---High oxygen content in general hydrogen;
---High hydrogen content in the air;
---High conductivity of pure water;
---High temperature of deoxygenation tower of the hydrogen purifier;
---High temperature of drying tower of the hydrogen purifier;
---High micro-oxygen of pure hydrogen;
---High dew point of pure hydrogen;
---Travel switch shows automatic valve failure;
---Mechanical ventilation system failure;
---Cooling water failure;
---Instrument air source failure;
---Power supply failure;
---Fire disaster.
8.7.5 Before new equipment is put into production, or, after overhauling, the automatic
control system shall receive tests and simulation tests, and comply with the following
requirements:
a) For each operation control unit or control loop, its operating procedures and
technical requirements shall comply with the stipulations of the production
process;
b) The interlocking control action shall be sensitive and reliable.
8.7.6 The uninterruptible power supply of the automatic control system shall be in a
normal condition at all times.
9 Operation and Maintenance
9.1 Preparation before First Actuation
9.1.1 It shall be confirmed that the various certificates and technical documents
provided by the manufacturer are complete and correct. These materials shall at least
include the following content:
a) Qualification certificate of the hydrogen production system and its main parts;
b) All routine test records;
c) Technical data and quality certification documents related to pressure vessels;
d) Texture certification documents of various parts, pipelines and accessories of
9.2.6 The operating personnel shall implement a patrol inspection system and promptly
deal with abnormal situations.
9.2.7 The cell voltage of the water electrolyzer shall be regularly measured; the voltage
of each cell shall be evenly distributed.
9.2.8 When an alarm or interlocking stop occurs during actuation or operation, the
cause shall be found out. In addition, it is strictly forbidden to arbitrarily change the
protection setting value or cancel the interlock.
9.2.9 When the hydrogen production system is shut down for a short time, the positive-
pressure state shall be maintained; when the hydrogen production system is shut down
for a long time, the hydrogen and oxygen in the system shall be evacuated and
replaced in accordance with the stipulations. After the replacement, the hydrogen
content shall not exceed 0.4% (volume fraction).
9.3 Equipment Maintenance
9.3.1 The maintenance and overhauling operations of the hydrogen production system
shall work out an operational scheme, which may be organized and implemented after
receiving approval.
9.3.2 The maintenance and overhauling operations shall execute the lockout / tagout
procedures.
9.3.3 In accordance with the requirements of the system maintenance manual, parts
of process equipment shall be regularly inspected, cleaned or replaced; the various
electrical equipment, instruments and meters shall be regularly inspected and
calibrated.
9.3.4 DO NOT arbitrarily knock on hydrogen equipment and pipelines. It is strictly
prohibited to disassemble equipment, pipelines or valves under pressure. The repair
and regular inspection of pressure vessels, and the periodic inspection of safety
accessories shall comply with the stipulations of TSG 21. The maintenance and regular
inspection of pressure pipelines shall comply with the stipulations of TSG D0001.
9.3.5 Before the hydrogen production system starts hot work, it shall be replaced after
reliable isolation, and pass the sampling analysis. The hot work shall strictly comply
with the stipulations of GB 30871.
9.3.6 Measures shall be taken during the equipment maintenance and overhauling
process, so as to prevent the parts in contact with oxygen from being contaminated
with grease.
9.3.7 When the safety facilities are being maintained, and there are no other alternative
measures, the operation of the protected equipment shall be stopped.
plans shall be revised and improved in time.
11.2 Leakage
11.2.1 The condition of leakage shall be quickly identified. In accordance with the
location and the extent of leakage, measures shall be taken to prevent or control the
leakage. In addition, in accordance with the stipulations of the emergency plans, the
leakage shall be reported.
11.2.2 Areas contaminated by hydrogen leakage shall be isolated; ventilation shall be
strengthened; ignition shall be strictly prohibited. The measures being taken shall also
comply with the stipulations of 8.5.5.
11.2.3 If a person is suffocated, he / she shall be rescued to a well-ventilated place in
time; artificial respiration shall be performed; medical treatment shall be promptly
sought.
11.2.4 When a small amount of alkaline liquor leaks, it may be absorbed and
neutralized by sand or weak acid; when a large amount of alkaline liquor leaks, the
drainage pipeline shall be closed, collected and recycled, or transported to a waste
disposal site for disposal.
11.2.5 Emergency treatment personnel shall wear personal protective devices to avoid
suffocation or burns by alkaline liquor.
11.3 Fire Disasters and Explosions
11.3.1 In case of a fire disaster or explosion of the hydrogen production system, the
power supply of the water electrolyzer shall be immediately switched off, and an alarm
shall be sent.
11.3.2 The hydrogen production system shall be maintained in a positive-pressure
state to prevent backfire; fire-fighting water mist shall be used for the forced cooling of
the equipment on fire.
11.3.3 Effective measures shall be taken to prevent the expansion of the fire, for
example, using a large amount of fire-fighting water mist to spray other igniting
substances and adjacent equipment.
11.3.4 Hydrogen flames are not easy to detect. The emergency treatment personnel
shall wear personal protective devices to prevent burns of exposed skin.
......
Source: Above contents are excerpted from the PDF -- translated/reviewed by: www.chinesestandard.net / Wayne Zheng et al.
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