BCGA CODE OF PRACTICE CP 33

The Bulk Storage of Gaseous Hydrogen

at Users’ Premises

Revision 1: 2012
 BCGA CODE OF PRACTICE CP 33
The Bulk Storage of Gaseous Hydrogen

at Users’ Premises

Revision 1: 2012

Copyright © 2012 by British Compressed Gases

Association. First printed 2005. All rights reserved.
No part of this publication may be reproduced or
transmitted in any form or by any means, electronic
or mechanical, including photocopy, without
permission from the publisher:

BRITISH COMPRESSED GASES ASSOCIATION

4a Mallard Way
Pride Park
Derby
DE24 8GX

Website: www.bcga.co.uk

ISSN 0260-4809

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BCGA CP 33 - Rev 1 - 2012
 PREFACE

The British Compressed Gases Association (BCGA) was

established in l971, formed out of the British Acetylene
Association, which existed since l901. BCGA members include
gas producers, suppliers of gas handling equipment and users
operating in the compressed gas field.

The main objectives of the Association are to further

technology, to enhance safe practice, and to prioritise
environmental protection in the supply and use of industrial
gases, and we produce a host of publications to this end. BCGA
also provides advice and makes representations on behalf of its
Members to regulatory bodies, including the UK Government.

Policy is determined by a Council elected from Member

Companies, with detailed technical studies being undertaken by
a Technical Committee and its specialist Sub-Committees
appointed for this purpose.

BCGA makes strenuous efforts to ensure the accuracy and

current relevance of its publications, which are intended for use
by technically competent persons. However this does not
remove the need for technical and managerial judgement in
practical situations. Nor do they confer any immunity or
exemption from relevant legal requirements, including by-laws.

For the assistance of users, references are given, either in the

text or Appendices, to publications such as British, European
and International Standards and Codes of Practice, and current
legislation that may be applicable but no representation or
warranty can be given that these references are complete or
current.

BCGA publications are reviewed, and revised if necessary, at

five-yearly intervals, or sooner where the need is recognised.
Readers are advised to check the Association’s website to ensure
that the copy in their possession is the current version.

This document has been prepared by BCGA Technical Sub-Committee 1. This

document replaces BCGA CP 33: 2005. It was approved for publication at BCGA
Technical Committee 143. This document was first published on 29/06/2012. For
comments on this document contact the Association via the website
www.bcga.co.uk.

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BCGA CP 33 - Rev 1 - 2012
 CONTENTS

Section Page

TERMINOLOGY AND DEFINITIONS 4

1 SCOPE 5

2 LOCATION OF HYDROGEN INSTALLATION 6

3 DESIGN OF INSTALLATION 7

3.1 General 7

3.2 Cylinders, tubes and medium pressure vessels 9

3.3 Piping 9

3.4 Testing 10

4 COMMISSIONING 11

5 HANDOVER AND OPERATION 12

5.1 The handover 12

5.2 Handover documents 12

6 PERIODIC EXAMINATION AND MAINTENANCE 12

7 REFERENCES 13

TABLE 1 Minimum recommended horizontal distances 15

APPENDICES:

APPENDIX 1 Example of gas data and safety sheet 16

APPENDIX 2 Examples of safety checks and written schemes for 18

hydrogen installations

APPENDIX 3 Installation in buildings 20

* Throughout this document numbers in brackets refer to references in Section 7.

Documents referenced are the edition current at the time of publication of this Code
of Practice.

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BCGA CP 33 - Rev 1 - 2012
TERMINOLOGY AND DEFINITIONS

Shall A mandatory requirement for compliance with this Code of

Practice.

Should A preferred requirement but this is not mandatory for

compliance with the Code of Practice.

May An option available to the user of this Code of Practice.

Hydrogen storage A gaseous hydrogen storage system is one in which the

contents have sufficient hydrogen to be flammable when
mixed with air and are stored or discharged in a gaseous
form. The system includes containers, pressure regulators,
instruments, safety-relief devices, manifolds, inter-
connecting piping and controls. The storage system
terminates at the point where hydrogen, at nominal service
pressure, enters the distribution piping.

Bulk storage For the purposes of this document bulk storage is defined as
hydrogen storage which consists of fixed cylinders
manifolded together, or tubes which may be either fixed in
place or mounted on a transportable trailer, or one or more
medium pressure vessels.

Cylinder Transportable pressure receptacle of up to 150 litres water

capacity.

Tube Seamless transportable pressure receptacle of between 150

and 3000 litres water capacity.

Medium pressure vessel A hydrogen storage vessel designed for fixed installation
only and working at up to 100 bar operating pressure.

Bundle A cylinder bundle, or manifolded cylinder pallet, consists of

a number of cylinders permanently manifolded to a
common outlet and contained in a rigid, protective
framework for ease of handling by forklift truck or crane.

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BCGA CP 33 - Rev 1 - 2012
 BCGA CODE OF PRACTICE CP 33
The Bulk Storage of Gaseous Hydrogen at Users’ Premises

1 SCOPE
This Code of Practice covers the location, design, installation, commissioning, operation and
maintenance of equipment for the bulk storage and supply of compressed hydrogen gas at
users’ premises.

This includes:

a) The issues surrounding safety distances around hydrogen installations, including

security, electrical classification, vehicle access, fire fighting, planning and
notification of relevant authorities.

b) Criteria for the design of the storage vessels, pressure and flow control
equipment.

c) Safety issues associated with the installation and commissioning of the

equipment.

d) Guidance on safe operation of the installation, both for the user and the gas
supplier.

e) Maintenance, including both preventive and routine, covering specific

requirements of UK legislation. This includes frequency and method for in-
service inspection.

f) Fixed systems refilled on site consisting of transportable pressure receptacles

(including cylinders, tubes or bundles) or medium pressure vessels.

Reference is made to relevant legislation, Codes of Practice and Standards, which are listed in
Section 7. The hazards and properties of compressed hydrogen are summarised in Appendix
1.

Compliance with the Pressure Equipment Regulations (PER) (4), The Equipment and
Protective Systems Intended for Use in Potentially Explosive Atmospheres Regulations (1),
The Dangerous Substances and Explosive Atmospheres Regulations (7) and the Pressure
Systems Safety Regulations (PSSR) (6) is mandatory. The materials and pressurised
equipment used for the installations will need to comply with the essential safety
requirements specified in the Regulations.

Compliance with the Management of Health & Safety at Work Regulations (5) will require
risk assessments to be carried out, which may include a formal HAZOP, during the process of
installation of bulk hydrogen systems.

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BCGA CP 33 - Rev 1 - 2012
This code does not include:

g) Liquid hydrogen. A summary of the requirements for safe operation with

liquid hydrogen is given in the European Industrial Gases Association (EIGA)
document 6/02 (14) or the USA National Fire Protection Association
document 55 (18).

h) Systems consisting only of transportable pressure receptacles that are not fixed
storage. For these systems see BCGA Code of Practice CP 4 (16).

2. LOCATION OF HYDROGEN INSTALLATION

The installation should whenever practicable be located outside in the open air. Other
locations may be considered after a suitable and sufficient risk assessment has been
completed. Detailed guidance on considerations for location inside buildings is given in
Appendix 3.

Hydrogen installations shall not be placed in pits where there is any restriction of the means
of escape in an emergency.

The installation shall be located so that it is readily accessible to delivery vehicles, to

authorised personnel and to emergency services. However, it shall be protected against
physical damage and access by unauthorised personnel. Fencing shall be provided unless
there is adequate control to prevent access by unauthorised persons.

On controlled sites with sufficient supervision fencing is optional.

Where fencing is provided the minimum clearance between the fence and the installation shall
be 0.6 m to allow free access to and escape from the enclosure.

The safety distances given in Table 1 will apply regardless of the position of the fence.

Timber or other readily combustible materials should not be used for fencing. The height of the
fencing should be at least 1.8 m.

Any gates should be outward opening and wide enough to provide for an easy access and exit
of personnel.

a) The main gate should have two wings, each at least 0.6 m wide.

b) The emergency exit gate should have one wing, at least 0.8 m wide.

Gates shall be locked during normal operation. Consideration should be given to the provision of
an additional emergency exit where the size of fenced area or equipment location necessitates this.

All the control equipment for the safe operation of the installation shall be easily accessible to
the plant operations personnel and delivery driver and all instrumentation shall be clearly
visible.

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BCGA CP 33 - Rev 1 - 2012
A site specific risk assessment shall be conducted to establish the acceptability of near by
electrical equipment or other sources of ignition.

Minimum separation distances of the installation from various hazards are given in Table 1.

NOTE: Table 1 does not apply to a delivery vehicle when the driver is present throughout
the delivery process.

Trailers which form part of the fixed installation shall comply with the safety distances.

Approval may be required for the installation from the local planning authority, the fire
authorities and the Health & Safety Executive. These requirements should be resolved with
the owners of the premises where the installation is planned.

3 DESIGN OF INSTALLATION

3.1 General

The design and installation shall comply with The Equipment and Protective
Systems Intended for Use in Potentially Explosive Atmospheres Regulations (1),
The Dangerous Substances and Explosive Atmospheres Regulations (7), The
Pressure Systems Safety Regulations (6) and The Pressure Equipment Regulations
(4).

3.1.1 The installation consists usually of fixed storage, which may be

provided either by a number of high pressure cylinders, tubes or bundles
manifolded together or by medium pressure vessel(s), together with a
pressure control station feeding the customer pipeline. The refilling of the
fixed storage is usually achieved by cascade from a transport trailer, with
control of the cascade process also carried out via the pressure control
station. An alternative is for the storage to be refilled by local hydrogen
generation and compression. In certain circumstances the fixed storage is
replaced by the use of multiple trailers. In all cases, the pressure-reducing
and control equipment shall be as close as practicable to the storage.

3.1.2 The installation shall be designed with a proper allowance for the
manoeuvring of the transport trailer and shall have adequate lighting.

3.1.3 The foundations of the fixed storage shall be designed to allow for
the loading imposed by the cylinders or medium pressure vessel(s). If
cylinders are used as the fixed storage they should be supported in a manner
to prevent corrosion resulting from standing in water, for example on metal
gratings or suitable supports.

3.1.4 In the case of multiple trailer installations, the trailers should be

sited to achieve adequate separation. This will mean at least 3.5 m between
centres.

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BCGA CP 33 - Rev 1 - 2012
 3.1.5 To prevent damage to equipment from the trailer, it is required,
where such a risk exists, to provide a “bump-stop” to alert the driver when
the trailer is in position, with at least 1 m clearance from the hazard.

3.1.6 Where two or more medium pressure vessels are required in an

installation the vessels shall be separated by at least 1 m at their closest
point. This does not apply to bundles.

3.1.7 An area classification drawing shall be prepared, indicating the

requirements for the use of appropriately classified electrical equipment, as
required under The Dangerous Substances and Explosive Atmospheres
Regulations (7). All electrical equipment shall then comply with these
requirements. BS EN 60079 (12) provides information.

3.1.8 A fire risk assessment shall be carried out. The assessment shall
identify fire-fighting requirements such as the volume and pressure of
available water. An emergency procedure shall also be drawn up following
completion of the risk assessment.

3.1.9 Adequate means of escape in case of emergency shall be provided.

In cases where personnel could be trapped inside compounds there shall be
not less than two separate outward opening exits remote from each other
and strategically placed with respect to the source of the hazard.

3.1.10 Notices shall be positioned so that they are visible from all sides of
approach to the installation. They should read:

HYDROGEN – FLAMMABLE GAS

NO SMOKING – NO NAKED FLAMES

These notices shall include “pictorial” symbols in accordance with the

Health and Safety (Safety Signs & Signals) Regulations (2). Compliance
with these Regulations is mandatory. These signs shall be supplemented by
a flammable material warning triangle. Examples are shown in Figure 1.

Figure 1. Examples of pictorial symbols.

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BCGA CP 33 - Rev 1 - 2012
 3.1.11 The area within 3 m of any hydrogen installation shall be kept free
of weeds and vegetation. If weed killers are used, chemicals such as
sodium chlorate, which is a potential source of fire danger, should not be
used.

3.1.12 Adequate means of giving alarm in the event of a fire shall be

provided. These should be clearly marked and suitably located at all
emergency exit points.

3.1.13 When the hydrogen is supplied from a tube trailer, a suitable and
sufficientanti-tow-away system must be provided.

3.2 Cylinders, tubes and medium pressure vessels.

Details of design requirement of cylinders, tubes and medium-pressure vessels are
not included in this document. Attention is drawn to the EIGA document 15/06 (15)
for information on medium-pressure vessel design requirements. Appendix 5 of that
document specifies, in Clause A.2.1.1, a maximum yield-strength of 420 MPa.
Compliance with this BCGA Code of Practice requires the adoption of 360 MPa for
this type of vessel and the use of post weld stress relief by heat treatment.

3.3 Piping

3.3.1 Piping and fittings shall be suitable for hydrogen service at the
pressure and temperature involved. Cast iron pipe and fittings shall not be
used. The design shall be to an appropriate, recognised design code.

3.3.2 Permanent joints (i.e. welded or brazed) are recommended.

Flanged or screwed joints are acceptable but their use should be minimised.
Compression fittings are generally not recommended, except where
essential for small bore instrument lines, when the manufacturer’s
instructions for assembly shall be strictly observed.

3.3.3 Vents shall be provided to enable the system to be depressurised in

a safe manner, for purging and at high and low points for testing.

3.3.4 All vents, including those of pressure relief devices, shall be

designed or located so that moisture cannot collect and freeze in a manner
which could interfere with the proper operation of the device.

3.3.5 Vents, including those of pressure relief devices, shall be arranged

to discharge in a safe place, into the open air. Normally this will be above
head height so as to prevent impingement of escaping gas upon any
personnel and structure. Pressure relief vents shall be piped individually
without manifolding, though manual vents may be manifolded where
design permits. They shall not discharge where gas could accumulate, such
as below the eaves of buildings. It should be noted that hydrogen can easily
ignite; vents should, therefore, be orientated to avoid any flame impinging
on vulnerable equipment, or the effects of radiated heat.

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BCGA CP 33 - Rev 1 - 2012
 3.3.6 Cabinets or housings containing hydrogen control or operating
equipment shall be adequately ventilated, particularly at high level, to
prevent accumulation of hydrogen in the event of leakage. They shall be
positioned so that, in the event of a leak, the gas can disperse in a safe
manner and the effects of any resultant fire can be minimised. If the
necessary ventilation is provided by mechanical systems then the
ventilation air shall be drawn from a safe place and an appropriate detection
/ alarm system should be installed to detect the failure of the ventilation
system or the presence of hydrogen well before a flammable concentration
is reached.

3.3.7 Relief valves shall be sized to allow for the worst foreseeable case,
i.e. regulator failure combined with full storage developed pressure at
60 °C.

3.3.8 Pipes should be installed above ground whenever practicable.

Where lines must be buried they shall be below the frost level. If pipes
must be run under roads or railways they shall be placed in pipe sleeves,
which are vented above ground to a minimum height of 3 m in a safe place.
The distribution pipework shall be in accordance with BCGA Code of
Practice CP 4 (16).

3.3.9 Isolation valves shall be provided so that the hydrogen source can
be shut off safely in the event of an emergency. This is particularly
important where hydrogen lines enter buildings.

3.3.10 The entire system must be continuously electrically earthed with a

maximum resistance to earth of 10 Ω or in accordance with national
standards whichever is the most stringent. The earthing connections should
be in position prior to a flammable mixture being present and also during
filling with, or emptying of, a flammable fluid. This shall include effective
earthing of the delivery vehicle. The earth rod for static earthing must be
solidly connected to earthing rods for electrical supplies or lightning
discharges. For lightning protection the installation should comply with BS
EN 62305 (13).

3.3.11 Pressure gauges. If bourdon tube type gauges are used the tube
must be specified to be either beryllium copper or phosphor bronze.

3.4 Testing

3.4.1 After installation all piping and fittings shall be, where practicable,
hydraulically and pneumatically tested. The system shall be thoroughly
dried out after these tests. Where it is not practicable to carry out a
hydraulic test prior to the pneumatic test, appropriate precautions shall be
taken as described in HSE Guidance Note GS-4 (10). The system shall be
helium leak tested or other suitable leak detection methods adopted prior to
the introduction of hydrogen.

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BCGA CP 33 - Rev 1 - 2012
 3.4.2 A final function test with hydrogen at maximum operating pressure
should be carried out after all pressure tests have been completed. Before
introducing hydrogen into the system all air shall be purged out using inert
gas. It shall be noted that hydrogen is an intensely searching gas and this
test should, therefore, be carried out in stages at progressively increased
pressure, checking carefully at each stage using an approved leak-detection
fluid.

4 COMMISSIONING
Before introducing hydrogen the whole system must be purged to ensure that air is removed
to a level safe for hydrogen operation. This shall be established by testing that the residual
oxygen concentration is less than 1 %.

Prior to the commissioning of a new hydrogen installation a thorough check shall be made to
ensure that:

a) The appropriate pressure and leak tests have been carried out and documented.

b) A check has been made that the installation conforms to the process and
instrumentation diagram.

c) A check has been made that the correct safety devices are fitted.

d) A check has been made that all warning and identification labels are clearly
displayed and that they are correct for the product being stored.

e) An ageing pressure equipment assessment in accordance with BCGA CP 39

(17) has been conducted to identify the in-service requirements.

f) A written scheme of examination in accordance with the Pressure Systems

Safety Regulations (6) has been drawn up by a competent person. A written
scheme of examination shall be required for the system. The responsibility for
providing and complying with this scheme lies with the user. Where systems
are leased or hired the user may transfer his responsibility to the owner by
written agreement (in accordance with the Pressure Systems Safety
Regulations, Schedule 2 (6)).

g) An initial examination has been completed if required by the above written

scheme.

h) Product release is minimised and controlled as far as is practicable.

i) Confirm that electrical equipment associated with the installation has been
certified by a competent person.

j) Confirm with the user that downstream pipework and equipment is compatible
with the default supply temperature and pressure conditions.

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BCGA CP 33 - Rev 1 - 2012
5 HANDOVER AND OPERATION
Operating instructions and flow sheets shall be permanently available at the installation and
accessible to drivers and operators.

Emergency telephone numbers and emergency procedures shall be prominently displayed.

Warning notices must be clearly visible from all sides of the installation.

The customer shall be instructed on the general safety aspects of hydrogen operation and on
the detailed operating instructions for the specific installation. Copies of the safety data sheet
shall be provided (Appendix 1 gives an example).

This may include warnings on the use of mobile phones, torches and test equipment, and the
use of anti-static footwear and clothing i.e. no nylon jackets.

The requirements of the Dangerous Substances and Explosive Atmospheres Regulations (7)
shall be complied with.

The owner or the installer shall be responsible for the handover to the user.

5.1 The handover. This shall include:

a) Training of user personnel in accordance with Section 6 , this may include a

demonstration of the correct operation of the equipment.

b) The provision of a contact address and telephone number should the user
have any questions about his installation.

c) An emergency telephone number.

d) A check to ensure that the user understands his responsibilities under the
Pressure Systems Safety Regulations (6) and has made arrangements for
them to be fulfilled.

5.2 Handover documents. These shall include a minimum of:

a) A manual covering safe operation of the installation.

b) An appropriate Safety Data Sheet, which gives information in accordance

with the requirements of the CHIP Regulations (8) and the REACH
Regulations (9). Safety Data Sheets provide information on hazardous
substances to help users conduct risk assessments. They describe the
hazards the product presents, and give information on handling, storage and
emergency measures in case of accident.

6 PERIODIC EXAMINATION AND MAINTENANCE

The installation will constitute a Pressure System within the Pressure Systems Safety
Regulations (6). As such a Written Scheme of Examination shall be drawn up by a
Competent Person, covering necessary checks and maintenance activities to ensure continued
safety from release of stored energy. Unless a written agreement exists with the customer
and the installation remains in the ownership of the Gas Company, the responsibility for

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BCGA CP 33 - Rev 1 - 2012
producing this Written Scheme and of carrying out the inspections under it lies with the User,
i.e. the customer. Many customers who do not wish to own the installation will prefer to
agree in writing with the Gas Company that this responsibility should be transferred to the
Gas Company.

Maintenance involving the use of heat or spark producing tools will require the system to be
purged with inert gas. Where no such hazard exists maintenance can be carried out without
purging.

Vessels, and other relevant parts of the system, shall periodically be examined in accordance
with the Written Scheme of Examination. Cylinders not classed as transportable pressure
receptacles, by virtue of their usage, shall also be included in the Written Scheme of
Examination. They will be purged with nitrogen for transport, if necessary. Examples of
Written Schemes of Examination for hydrogen installations are given in Appendix 2. An
ageing pressure equipment assessment in accordance with BCGA CP 39 (17) shall be
conducted to identify additional ageing related in-service requirements not included in the
sample written scheme in Appendix 2.

In the case of installations including medium pressure vessel(s) a log shall be maintained of
the pressure cycling experienced by the vessel(s) in service. This involves recording each fill
carried out with the date and the pressure before and after filling. See Appendix 2.

7 REFERENCES

1. SI 1996 No 192 The Equipment and Protective Systems Intended for Use in
Potentially Explosive Atmospheres Regulations 1996.

2. SI 1996 No. 341 The Health and Safety (Safety Signs and Signals)
Regulations 1996.

3. SI 1997 No. 1713 The Confined Spaces Regulations 1997.

4. SI 1999 No. 2001 The Pressure Equipment Regulations 1999.

5. SI 1999 No 3242 The Management of Health and Safety at Work Regulations

1999, as amended.

6. SI 2000 No. 128 The Pressure Systems Safety Regulations 2000.

7. SI 2002 No 2776 The Dangerous Substances and Explosive Atmospheres

Regulations 2002.

8. SI 2009 No. 716 The Chemicals (Hazard Information and Packaging for
Supply) Regulations 2009 (CHIP Regulations).

9. Regulation (EC) No European Commission - Registration, Evaluation,

1907/2006 Authorisation and restriction of Chemicals. (REACH), as
amended.

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BCGA CP 33 - Rev 1 - 2012
 10. HSE Guidance Note Safety in pressure testing. 1998.
GS4
11. BS 476 Fire tests on building materials and structures.

12. BS EN 60079 Explosive atmospheres.

13. BS EN 62305 Protection against lightning.

14. EIGA IGC Document Safety in storage, handling and distribution of liquid
6 / 02 hydrogen.

15. EIGA IGC Document Gaseous hydrogen stations.

15 / 06

16. BCGA Code of Industrial gas cylinder manifolds and distribution pipework
Practice 4 (excluding acetylene).

17. BCGA Code of In-service requirements of pressure equipment installed at

Practice 39 user premises.

18. NFPA 55 Compressed gases and cryogenic fluids code

Further information can be obtained from:

Health and Safety Executive www.hse.gov.uk

HSE Books www.hsebooks.co.uk

HMSO www.hmso.gov.uk

BSi www.bsigroup.co.uk

EIGA www.eiga.eu

BCGA www.bcga.co.uk

USA - National Fire www.nfpa.org

Protection Association

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BCGA CP 33 - Rev 1 - 2012
TABLE 1 - MINIMUM RECOMMENDED HORIZONTAL DISTANCES

If a firewall is used, a minimum separation distance of 3 m should be maintained between the

wall and any part of the trailer or fixed installation that could provide a likely ignition point.
The distances shown above are horizontal distances. Where specified hazards exist vertically
above the installation special considerations apply. A formal risk analysis will be needed to
assess the requirements.

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BCGA CP 33 - Rev 1 - 2012
 APPENDIX 1
Sheet 1 of 2
EXAMPLE SAFETY DATA SHEET

HYDROGEN

1 IDENTIFICATION OF THE 6 ACCIDENTAL RELEASE MEASURES

SUBSTANCE/PREPARATION AND OF THE COMPANY
MSDS Nr Personal precautions
067A A flammable gas detector should be used before entering an area.
Product name Evacuate area. Ensure adequate air ventilation.
Hydrogen Eliminate ignition sources.
Chemical formula Environmental precautions
H2 Try to stop release.
Company identification Clean-up methods
see footer Ventilate area
Emergency ‘phone numbers
see footer

2 COMPOSITION/INFORMATION ON INGREDIENTS 7 HANDLING AND STORAGE

Substance/Preparation Ensure equipment is adequately earthed.
Substance Suck-back of water into the container must be prevented.
Components/impurities Purge air from system before introducing gas.
Contains no other components or impurities which will influence Do not allow back-feed into the container.
the classification of the product Use only properly specified equipment which is suitable for this
CAS Nr product, its supply pressure and temperature. Contact your gas
01333-74-0 supplier if in doubt.
EEC Nr (from EINECS) Keep away from ignition sources, including static discharge.
2156057 Segregate from oxidant gases and other oxidants in store.
Refer to supplier’s container handling instructions.
Keep container below 50 oC in a well-ventilate place.

3 HAZARDS INDENTIFICATION 8 EXPOSURE CONTROLS/PERSONAL PROTECTION

Hazards identification Personal protection
Compressed gas Ensure adequate ventilation.
Extremely flammable Do not smoke while handling product

4 FIRST AID MEASURES 9 PHYSICAL AND CHEMICAL PROPERTIES

Inhalation Molecular weight
In high concentrations may cause asphyxiation. Symptoms may 2
include loss of mobility/consciousness. Victim may not be aware Melting point
of asphyxiation. -259 oC
Remove victim to uncontaminated area wearing self-contained Critical temperature
breathing apparatus. -240 oC
Keep victim warm and rested. Call a doctor. Relative density, gas
Apply artificial respiration if breathing stopped. 0.07 (air =1)
Ingestion Relative density, liquid
Ingestion is not considered a potential route of exposure. 0.07 (water =1)
5 FIRE FIGHTING MEASURES Vapour pressure 20 oC
Specific Hazards Not applicable
Exposure to fire may cause containers to rupture/explode Solubility mg/l water
Burns with a colourless, invisible flame 1.6 mg/l
Hazardous combustion products Appearance/Colour
None Colourless gas
Suitable extinguishing media Odour
All known extinguishants can be used None
Specific methods Auto-ignition temperature
If possible, stop flow of product. Move container away or cool 560 oC
with water from a protected position Flammability range
Do not extinguish a leaking gas flame unless absolutely necessary. 4-75 vol % in air
Spontaneous/explosive re-ignition may occur. Other data
Extinguish any other fire. Burns with a colourless, invisible flame
Special protective equipment for fire-fighters
In confined space use self-contained breathing apparatus

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BCGA CP 33 - Rev 1 - 2012
 APPENDIX 1
Sheet 2 of 2

10 STABILITY AND REACTIVITY 15 REGULATORY INFORMATION

Stability and reactivity Number in Annex 1 of Dir 67/548
Can form explosive mixture with air. 001-001-00-9
May React violently with oxidants. EC Classification
F+;R12
11 TOXICOLOGICAL INFORMATION Symbols
General F+: Extremely flammable
No known toxicological effects from this product. R Phrases 12
S Phrases 9-16-33
12 ECOLOGICAL INFORMATION Labelling of cylinders
General Symbols Label 3: flammable gases
Risk phrases R12 Extremely flammable
No known ecological damage caused by this product. Safety phrases S9/16/33 Keep container in well-ventilated place,
away from ignition sources, including static discharge.
13 DISPOSAL CONSIDERATIONS
General
Do not discharge into areas where there is a risk of forming an
explosive mixture with air.
Waste gas should be flared through a suitable burner with
flash-back arrestor.
Do not discharge into any place where its accumulation could
be dangerous.
Contact supplier if guidance is required.

14 TRANSPORT INFORMATION 16 OTHER INFORMATION

UN Nr Ensure all national / local regulations are observed.
1049 Ensure operators understand the flammability hazard.
Class/Div The hazard of asphyxiation is often overlooked and must be stressed
2.1 during operator training.
ADR/RID Item No Before using this product in any new process or experiment, a
ADR RID Item No thorough material compatibility and safety study should be carried
2, 1 ºF out.
ADR RID Hazard Nr Details given in this document are believed to be correct at the time of
230 going to press
Labelling ADR Whilst proper care has been taken in the preparation of this document,
Label 3: flammable gas no liability for injury or damage resulting from its use can be
accepted.
Other transport information

Avoid transport on vehicles where the load space is not separated

from the driver’s compartment.
Ensure vehicle’s driver is aware of the potential hazards of the load
and knows what to do in the event of an accident or an emergency.
Before transporting product containers, ensure that they are firmly
secured and:
• cylinder valve is closed and not leaking
• valve outlet cap nut or plug (where provided) is correctly fitted
• valve protection device (where provided) is correctly fitted
• there is adequate ventilation
• compliance with applicable regulations.

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BCGA CP 33 - Rev 1 - 2012
 APPENIDX 2
Sheet 1 of 2

EXAMPLES OF SAFETY CHECKS AND WRITTEN SCHEMES FOR HYDROGEN

INSTALLATIONS

1 Installations consisting of cylinder or trailer storage with pressure / flow control cabinet.

Safety Checks

Every year, carry out the following safety checks, which form part of normal, regular
maintenance of the installation:

a) Where practicable, full leak check of system using approved leak detection
fluid. If leaks are found the system shall be depressurised before repairs are
carried out. Any hot work will involve purging out of hydrogen with inert gas
and a re-test with nitrogen or water before re-introducing hydrogen.

b) Pressure gauges will be checked for correct operation.

c) Relief valves will be checked externally for correct seal in place, clear outlet
and security of installation.

d) Physical inspection of whole system for any external damage

e) Inspect high pressure transfer hose for condition and replace if necessary.

Written scheme of examination

Every 5 years:

f) Replace high pressure transfer hose.

g) Replace relief valves with new or refurbished unit.

Every 10 years:

h) Remove and replace cylinder manifolds with new or refurbished units.

i) Where necessary, purge cylinders with nitrogen, remove them and transport
for re-testing.

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BCGA CP 33 - Rev 1 - 2012
 APPENDIX 2
Sheet 2 of 2

2 Installations incorporating one or more medium pressure vessels with pressure / flow
control cabinet.

Safety Checks

Every year, carry out the following safety checks, which form part of normal, regular
maintenance of the installation:

a) Where practicable, full leak check of system using approved leak detection
fluid. If leaks are found the system shall be depressurised before repairs are
carried out. Any hot work will involve purging out of hydrogen with inert gas
and a re-test with nitrogen or water before re-introducing hydrogen.

b) Pressure gauges will be checked for correct operation.

c) Relief valves will be checked externally for correct seal in place, clear outlet
and security of installation.

d) Physical inspection of whole system for any external damage

e) Inspect high pressure transfer hose for condition and replace if necessary.

Written scheme of examination

5 years after putting into service and every 5 years thereafter:

f) Replace relief valves with new or refurbished unit.

g) The external examination of the medium pressure vessel(s) specified above at

2 years is to be repeated.

h) Either: Where practicable external ultrasonic flaw detection of all main seam
welds, with the capability of detecting cracks 3 mm in length.

or,

internal inspection of the inside surface of the vessel(s), with magnetic particle
inspection of the welds. The requirements of the Confined Spaces Regulations (3)
must be complied with.

i) Replace high pressure transfer hose.

NOTE: The pressure cycling data on medium pressure vessels collected (see Section 6) shall
be reviewed by the Competent Person to assess the necessary frequency of the vessel
examination.

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 APPENDIX 3
Sheet 1 of 2
INSTALLATION IN BUILDINGS

Storage
Cylinders or bundles of hydrogen may be stored together with other common flammable
gases, excluding LPG, inside a building used only for the storage of cylinders provided that
the following requirements are met:

a) The building shall be of non-combustible material in accordance with BS

476 Part 4 (11).

b) The hydrogen cylinders shall be separated from other cylinders of flammable

gas by not less than 1 metre.

c) The building shall have good high and low level natural ventilation to the open
air. Outlet openings shall be located at the highest point of the room in
exterior walls or roof. Vent openings shall have a minimum total area of not
less than 2.5 % of the combined area of the walls and roof of the building.

d) Adequate explosion relief shall be provided in exterior walls or roof of the

building. The total relieving area shall not be less than either the area of the
roof or the area of one of the longest sides.

This explosion relief should be designed so that if an explosion occurs the pressure
would be relieved and yet the explosion relief materials would not be likely to
become dangerous missiles. Any combination of the following would be suitable:

(i) Walls of light non-combustible material, preferably single thickness.

(ii) Lightly fastened hatch covers.

(iii) Lightly fastened doors in exterior walls opening outwards.

(iv) Walls or roof of light design and lightly fastened.

e) Heating, if provided, shall preferably be by hot water or warm air. Where

recirculatory systems are used consideration shall be given to the possibility of
hydrogen contamination and adequate precautions shall be taken. The heat
sources should be located remote from the building and comply with the
distances set out in Table 1. Where an electrical source for heating is located
in a hazardous area it shall comply with the requirements for electrical
equipment outlined in Section 3.1.7.

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 APPENDIX 3
Sheet 2 of 2

Installation
Hydrogen systems of less than 200 cubic metres capacity may be located in buildings used
for other purposes provided that the installation meets the following requirements:

a) It shall be in a well ventilated area with good high and low level natural
ventilation.

b) It shall be protected against damage due to falling objects or work activity in

the area.

c) It shall not be close to or below lines containing other flammable gases or

liquids.

d) It shall not be located below electric lines or equipment.

e) It shall comply with the distances in Table 1.

f) It shall be defined by means of conspicuous markings and not be used for

storing other materials.
British Compressed Gases Association
www.bcga.co.uk