2024年氢能行业的功能安全工业信息安全和防爆保护白皮书.pdf

Functional safety,Industrial Security and explosion protection for the hydrogen industry White paper Status:July 2024 White paper Functional safety,Industrial Security and explosion protection for the hydrogen industry 2024-07|Pilz GmbH&Co.KG,2024|2 of 31 Exclusion of liability Our white paper has been compiled with great care.It contains information about our company and our products.All details are provided in accordance with the current state of the art and to the best of our knowledge and belief.However,we cannot accept liability for the accuracy and entirety of the information provided,except in the case of gross negligence.In particular,it should be noted that statements do not have the legal quality of assurances or assured properties.We are grateful for any feedback regarding the content.Copyright and proprietary notices All rights to this publication are reserved by Pilz GmbH&Co.KG.Copies may be made for internal purposes.The names of the products,goods and technologies used are trademarks of the respective companies.Pilz GmbH&Co.KG Felix-Wankel-Strae 2 73760 Ostfildern Germany 2024 by Pilz GmbH&Co.KG,Ostfildern 1st Edition White paper Functional safety,Industrial Security and explosion protection for the hydrogen industry 2024-07|Pilz GmbH&Co.KG,2024|3 of 31 At a glance In order to reach net zero CO2 emissions by 2050,global efforts are concentrated on decarbonisation of the energy supply.CO2-neutral hydrogen plays a key role in this goal.For all those involved in the hydrogen value chain sectors manufacturers,operators,users,notified bodies and insurers the primary objective is to keep the risk of an accident below a socially acceptable residual risk.This applies not only during design and engineering,but also for operation and maintenance particularly relevant in the energy supply sector and also to guarantee business continuity.Pilz supports the challenges of stakeholders with its many years of experience in the global automation industry.In this white paper we focus on the different elements of the overall hydrogen chain and provide a short description of the key safety-related requirements.In view of all the opportunities that arise from the impressive properties of hydrogen,it is worth emphasising that broad social acceptance of the use of new technologies develops when thinking extends beyond mere compliance with legal requirements,industrial regulations or technical standards.Each safety-related incident delays the introduction of new technologies.However,we are convinced that when proven solutions are used,the number of safety-related incidents will in no way develop in parallel to the spread of hydrogen technology.Nonetheless,it is important to be aware:even in the future,bad news will continue to sell better than good news.The answer is to get it right from the start!To achieve lasting,reliable safety,it is essential to use proven procedures and tools for the risk analysis,risk evaluation,and when developing plant and machinery.In numerous discussions with manufacturers,users,organisations and associations we see uncertainty when dealing with the safety requirements.Thats why in this document we look in more detail at the different hydrogen applications and their specific standards and requirements.If you would like to get in touch with us,you can use the contact options at We look forward to hearing from you!White paper Functional safety,Industrial Security and explosion protection for the hydrogen industry 2024-07|Pilz GmbH&Co.KG,2024|4 of 31 Contents 1.Introduction.5 1.1.Process industry and Machinery Safety Similarities and differences.6 1.2.What are the risks when using hydrogen?.6 1.3.Basic explanation The term“functional safety”.7 1.4.Explosion protection.11 2.Legal framework for hydrogen.12 3.Industrial Security for the hydrogen industry.14 3.1.1.Foreseeable misuse,faulty operation.15 3.1.2.Simplification of organisational measures.17 4.General safety aspects.18 4.1.Sensors for detecting leaks,gas concentrations and flames.19 4.2.Monitoring of process values.19 4.2.1.Safe pressure monitoring.22 4.2.2.Safe temperature monitoring.22 5.Application examples.22 5.1.Hydrogen production.25 5.2.Electrolyser.25 5.3.Steam reforming.26 5.4.Hydrogen refuelling stations.26 5.5.Hydrogen consumers.27 5.5.1.Fuel cell.27 5.5.2.Burner.27 5.5.3.Combustion engine.29 6.Conclusion.30 White paper Functional safety,Industrial Security and explosion protection for the hydrogen industry 2024-07|Pilz GmbH&Co.KG,2024|5 of 31 1.Introduction Hydrogen has incredible potential when it comes to addressing the key questions of future energy supply.At the same time,questions regarding acceptance always arise when new technologies are introduced.The aim is to improve all aspects of technical,commercial,environmental and global strategic criteria.Usually this task can only be tackled step by step,and provides ever clearer and more plausible answers in a retrospective view than is ever possible by looking ahead.However,it is important to take account of empirical values from other,comparable applications and bring about better,safer solutions including by analogy.This requires close interaction and cross-sector exchange.The market ramp-up of the entire hydrogen value chain is a key task for all concerned.The use and transfer of industrially-proven principles requires open co-operation.The industrial production and use of hydrogen is not a new technology but the applications and application areas have undergone considerable changes.In addition to upscaling to larger mass flows,completely new application areas will also emerge.Today,experience in handling hydrogen exists primarily in large-scale processing plants whereas direct contact with consumers was rather a rarity in the past.Decentralisation of the energy supply is a clearly stated goal whereby the user group also changes and therefore requires special consideration.In addition to global strategic and economic considerations,increasing market share is also fundamentally dependent on social acceptance.And the ability to handle technology safely plays a key role.The task is to guarantee safety for all applications and all potential levels of qualification from a qualified,trained professional to an untrained consumer at the refuelling station.White paper Functional safety,Industrial Security and explosion protection for the hydrogen industry 2024-07|Pilz GmbH&Co.KG,2024|6 of 31 1.1.Process industry and Machinery Safety Similarities and differences There are some similarities-but also differences in the safety philosophy of the process industry and Machinery Safety.In particular,it is worth considering the target group for which the safety measures are primarily designed and which qualifications may be required there.The market ramp-up and increased market share mean that large-scale industrial users are not the only ones coming into contact with potentially dangerous materials and substances so too are untrained technical laypeople.The basic philosophy of industrial safety technology is that humans must always be protected from hazards and risks must be averted.A safety-related worst-case assessment must always be designed to consider the weakest link in a chain and this is generally the human.Process industry Machinery Safety Safety-related analyses LOPA,HAZOP,PHA Hazard and risk analysis for each hazard Hazard due to Harmful substances Heat,steam,radiation,leakage,electricity,but mainly due to failure of the control system Moving machine parts(shearing,crushing.)Hazards arising from the(manufacturing)process Safe reaction through monitoring Typically alarm,followed by operator intervention Different levels of protection Process control safety device Stopping of hazardous processes(e.g.machine movement)Automatic,direct,safe intervention in the control sequence Reaction time Adjusted to the process reaction(seconds.hours)Immediate(milliseconds)Environment Plant and its environment Limited locally to the plant/machine Organisational measures for Experts(monitored workflows,check lists,comprehensive documentation)Machine operator,trained for the production order Protection against manipulation Safety philosophy Safety design for highly qualified and trained professionals Safety design for all,occasionally beginners,who have not had detailed training Table:Comparison of safety measures in the process industry and in Machinery Safety 1.2.What are the risks when using hydrogen?Hydrogen in conjunction with oxygen is a highly explosive gas mixture;it is often under high pressure and is extremely cold in its liquid state.This requires extensive protective measures during manufacture,transport and processing.Hydrogen and oxygen have an extremely wide flammability range of 4 to 78 per cent by volume,at which ignition or an explosion can occur.At White paper Functional safety,Industrial Security and explosion protection for the hydrogen industry 2024-07|Pilz GmbH&Co.KG,2024|7 of 31 the same time,hydrogen requires a much lower ignition energy than petrol or natural gas,for example,as a result of which it can ignite much more easily.For this reason,when designing hydrogen devices and containers it is vitally important that adequate ventilation and/or leak detection is available.Because hydrogen burns with a flame that is almost invisible,special flame sensors are also required.The selection of appropriate materials is also important for designing durable,robust hydrogen containers.Metals can become brittle when exposed to hydrogen.Given its small molecule size,it can leak through the smallest of tears or material transitions.There are a large number of risks connected to the manufacture,processing and storage of hydrogen,which must be considered.Fire,explosion and asphyxiation are the most important safety aspects that must be considered when handling hydrogen.Particularly in the context of the wide flammability range of 4%to 78%of the H2 volume in air.Leakage:Due to its small molecule size,low molecular weight,high diffusivity and low viscosity,hydrogen is very difficult to contain and can easily leak.Hydrogen leaks pose a serious risk of fire or explosion.It is generally assumed that in enclosed spaces it will rise to the ceiling,displacing the oxygen.Consequently it is very difficult to detect in spaces where accumulations can occur.Pressurised hydrogen leaks can be even harder to detect as the direction of the gas jet as it escapes from a pipe or container can be unpredictable.This makes it more difficult to position an appropriate sensor.Fire/ignition:Hydrogen is highly flammable and naturally explosive.It ignites and burns much more easily than other fuels,and as one of the lightest elements on earth,it spreads upwards very quickly.Hydrogen flames are invisible,which makes it difficult to localise the fire source.When mixed with air,hydrogen is highly combustible.However,a pure hydrogen flame is very pale and almost invisible in daylight.Contact injury:Because hydrogen is normally stored and transported in liquid state in pressurised hydrogen tanks,it is extremely cold.If hydrogen escapes in this state and comes into contact with the skin or if the icy vapour of the liquid hydrogen is inhaled,this can lead to burns,frostbite,hypothermia and lung damage.Safety precautions are essential to ensure safe application.Detection technologies combined with safe control technology play a key role in safe use and also in avoiding damage and accidents.1.3.Basic explanation The term“functional safety”Standards and regulations guarantee that industrial plant and machinery is safe to use.They cover a wide range of machinery and equipment,focusing on essential health and safety requirements.Whether its an assembly line or a single machine,compliance with these regulations is crucial for protecting employees and preventing accidents.Also,risk assessments are essential to ensure that machinery is designed and constructed to minimise risks during operation and in the event of foreseeable misuse.“Functional safety”is the term used when safety depends on the correct function of a control system.However,functional safety does not only consider the current state of a plant or machine considerations over the whole lifecycle also play a role in the assessment.The White paper Functional safety,Industrial Security and explosion protection for the hydrogen industry 2024-07|Pilz GmbH&Co.KG,2024|8 of 31 standards for functional safety include risk analysis,specification of requirements,validation,regular function tests and commissioning.Risk assessment plays a central role with regard to functional safety requirements.The steps you need to consider when assessing and reducing risk on machinery come from the standard EN ISO 12100:General principles for design Risk assessment and risk reduction.The evaluation and verification of safety functions are the prevail of the standards EN ISO 13849:Safety-related parts of control systems and EN IEC 62061:Safety integrity levels(SIL),provided the required safeguarding is dependent on a control system.The safety integrity requirements(PL,SIL)are derived from the risk estimation.According to EN IEC 61508:Functional safety of electrical,electronic and programmable electronic safety-related systems,safety integrity refers to the effectiveness of the safety functions of a safety-related system.When looking to determine the effectiveness,the whole chain of all the elements involved in the safety function are always considered,i.e.Appropriate sensor to safely record safety-related process variables Appropriate controller to safely evaluate process states Appropriate actuator to safely influence process variables(control,regulation)With the complexity of the systems and safety-related requirements,electronic systems are increasingly being used,especially programmable controllers.These are used,for example,to monitor the pressure,temperature,speed,flow rate and levels in safety-related applications.The standard series EN IEC 61511:Functional safety covers safety issues on plants and systems in the process industry.As a sector standard of EN 61508,the EN IEC 61511 series is a sister standard of EN IEC 62061.This is reflected in the similar observations and mathematical principles contained in the three standards.However,an important difference for most end users and component manufacturers is the distinction between operating modes with low or high demand rate.In the process industry,plants are generally designed in such a way that a safety function is processed with a low demand rate.According to EN IEC 61511-1,a failure is the termination of the ability of an item to perform a required function.In functional safety,a distinction is made between random and systematic errors.Random hardware failures are hardware failures that occur statistically and with a reproducible probability on electronic components.The failure rates determined in functional safety can therefore only