# TEST PURPOSE

## PURPOSE

This document contains an analysis of the hazards involved with the
performance of tests with the IHOPP test article described in
ESTA-TP-8F016. Controls are defined to mitigate the hazards and an
assessment of the risk remaining is made.

## SCOPE

This hazard analysis covers the hazards of handling and operating the
test article as well as the hazards involved in integrated operation of
the test article with the facility. Hazards involved in the operation of
facility systems that are not specific to this test program are covered
in the hazard analyses for those facility systems.

## SYSTEM PURPOSE

The purpose of this system is to provide a test bed for single cell
testing of Proton Exchange Membrane (PEM) Membrane Electrode Assemblies
(MEAs). See the test plan ESTA-TP-6F001 for objectives and scope of
effort.

## SYSTEM FUNCTIONAL DESCRIPTION

The system provides pressure control, temperature control, and
humidification control of hydrogen and oxygen and provides these gases
on demand to a PEM fuel cell MEA. System 626 -- the general purpose fuel
cell test stand, will be the reactant and inert supply system for the
Globe Tech test unit and will have the capability to switch from
reactants to inert nitrogen for purging.

# HAZARD ANALYSIS SUMMARY

Hazards for this test program are listed below.

## ELECTRICAL POTENTIAL: 

Standard 120V AC power is required for test system instrumentation. The
fuel cells should produce up to 1.2 Volts per cell during operation.
Additional safety controls for this low voltage are not necessary.

## SHRAPNEL OR BLAST WAVE OVER-PRESSURIZATION:

No hazards beyond standard pressure system hazards exist

## FIRE

Fire hazards exist due to the presence of hydrogen and oxygen for this
test. This test shall be performed in Building 356E, Cell126. This test
cell is equipped with three point hydrogen sensors. The cell is also
equipped with a water deluge system with an increasing temperature,
rate-of-rise automatic trip sensor in the cell and a manually operated
switch in the Bldg. 356 control room.

## HIGH TEMPERATURES:

Temperatures of the fuel cell can reach up to 165^o^ F. Warning
statement in procedures and visual warnings on the fuel cell stack shall
control this hazard. The fuel cell and the fuel cell test stand are
Category D pressure systems certified. Therefore, a blast wall shall
remain between the operator and the test stand during test operations.

## LOW TEMPERATURES:

None

## IONIZING RADIATION:

None

## HIGH ENERGY ELECTROMAGNETIC FIELDS:

None

## OXYGEN DEFICIENT ATMOSPHERES:

System 624 provides oxygen monitoring functions for the test systems in
Cell 126 of Bldg. 356E. Alarms are sounded when oxygen levels fall below
19.5% by volume. During any testing in Building 356E, Cell 126, the
oxygen monitoring system provides a continuous warning capability.

## TOXIC ATMOSPHERE:

None

## HIGH SOUND LEVELS:

None

## SHARP POINTS OR EDGES:

None

## COLLISIONS:

None

## CRUSHING FORCES:

None

## ENVIRONMENTAL POLLUTION:

None

## TEST ARTICLE:

This test article is a single cell PEM fuel cell MEA. The test is
designed to characterize failures of MEAs, and therefore failures are
expected. Risks such as crossover of hydrogen and oxygen might occur,
along with high temperatures on the test article. PPE, test cell hazard
controls, and instrumentation shall be required to identify and control
hazardous situations. The PLC constantly monitors the fuel cell
conditions and shuts off the reactants to the fuel cell immediately upon
reaching a shutdown condition. The PLC shuts of Solenoid Valves SV-212
and SV-112 closely upstream of the fuel cell and turns off Electronic
Regulators (ER-4415 and ER-4420 on System 626 to shut off reactants
upstream and downstream of the Globe Tech system.

# DOCUMENTS REVIEWED

## DRAWINGS AND COMPONENT LISTINGS

## Schematic 6F001 {#schematic-6f001 .unnumbered}

## HAZARD ANALYSIS REPORTS

None

## OTHER DOCUMENTS

EA-367 Hazard Analysis Preparation Procedure

JSC 17773C Instructions for Preparation of Hazard Analysis Reports

EP-WI-004 ESTA General Operating Procedures Manual

JHB-1710.13B Design, Inspection, and Certification of Pressure Vessels
and Pressurized Systems

# SUPPORTING INFORMATION

## RISK ASSESSMENT CODES (RAC's)

  ------------------------------------------------------------------------------------------------------------
  **[Severity                                              **[Probability         
  Codes]{.underline}**                                     Codes]{.underline}**   
  ---------------------- --------------------------------- ---------------------- ----------------------------
  **I**                  **Catastrophic** - Death, several **A**                  **Frequent** - Likely to
                         serious injuries or illnesses, or                        occur one or more times per
                         damage over \$1,000,000.                                 year.

  **II**                 **Critical** - Serious injury or  **B**                  **Probable** - Likely to
                         illness, several lost workdays,                          occur once in 1 - 2 years.
                         or damage between                                        
                         \$250,000-\$1,000,000.                                   

  **III**                **Marginal** - Lost workday,      **C**                  **Occasional** - May occur
                         several minor injuries, or damage                        once in 2 - 5 years.
                         between \$25,000-\$250,000.                              

  **IV**                 **Negligible** - Minor injury or  **D**                  **Remote** - Unlikely to
                         damage less than \$25,000.                               occur, but possible within 5
                                                                                  years to end of system life.
  ------------------------------------------------------------------------------------------------------------

  ----------------- --------- ----------------- ------------- ------------- -------------
  **RAC**                     **Probability**                               

  **Assignment:**             **A**             **B**         **C**         **D**

                    **I**     1                 1             2             3

  **Severity**      **II**    1                 2             3             3

                    **III**   2                 3             4             4

                    **IV**    3                 3             4             4
  ----------------- --------- ----------------- ------------- ------------- -------------

  ----------------------------------------------------------------------------------------
  **[RAC]{.underline}**   **[Description - Action]{.underline}**
  ----------------------- ----------------------------------------------------------------
  **1**                   **Unacceptable** - Correct within 24 hours using temporary or
                          permanent engineering or administrative controls to reduce the
                          hazard to a RAC 3 or 4. All operations must cease immediately
                          until the hazard is corrected or until temporary controls are in
                          place and permanent controls are in work. A safety professional
                          should stay at the scene at least until temporary controls are
                          in place.

  **2**                   **Undesirable** - Correct within 3 working days using
                          engineering or administrative controls to reduce the hazard to a
                          RAC 3 or 4 or less. All operations must cease immediately until
                          the hazard is corrected or until temporary controls are in place
                          and permanent controls are in work. Program Manager or Center
                          Director may accept the risk with adequate justification.

  **3**                   **Acceptable with controls** - Correct hazard within 30 days and
                          verify that documented procedures and controls are in place.
                          Organizational Director or equivalent management may accept the
                          risk with adequate justification.

  **4**                   **Acceptable with controls** - Correct hazard within 90 days.
                          Division Chief or equivalent management may accept the risk with
                          adequate justification.
  ----------------------------------------------------------------------------------------

# DISTRIBUTION

Original EP6 / Test Manager\
EP6 / Branch Chief\
EP6 / Branch Test File\
EP6 / LM Supervisor\
EP6 / Building 356\
EP6 / ESTA Safety\
NS2 / Safety and Test Operations

+-------+---------+---------+----+--------------+----------+------+
| H     | CAUSE   | EFFECT  | S  | CONTROLS     | VERI     | DIS  |
| AZARD |         |         | ev |              | FICATION | POSI |
|       |         |         | /P |              |          | TION |
|       |         |         | ro |              |          |      |
|       |         |         | b\ |              |          | Sev  |
|       |         |         | R  |              |          | Prob |
|       |         |         | AC |              |          | RAC  |
+=======+=========+=========+====+==============+==========+======+
| Elect | Energ   | Ele     | I  | Support      | Review   | Co   |
| rical | ization | ctrical | /  | systems:     | system   | ntro |
| Pote  | of      | burns,  | B\ | National     | confi    | lled |
| ntial | Con     | Resp    | 1  | Electrical   | guration | Risk |
|       | ductive | iratory |    | Code         | and      |      |
|       | s       | and/or  | I  | compliance,  | training | I /  |
|       | urfaces | Cardiac | /  | UL-certified | records. | D\   |
|       | after   | Arrest  | B\ | commercially |          | 3    |
|       | Random  | due to  | 1  | acquired     | Review   |      |
|       | Ele     | ele     |    | equipment,   | system   | I /  |
|       | ctrical | ctrical |    | and          | confi    | D\   |
|       | Fault,  | current |    | equipment    | guration | 3    |
|       | O       | flow    |    | chassis      | and      |      |
|       | perator | through |    | properly     | training | I /  |
|       | Error   | victim  |    | grounded, as | records. | D    |
|       | or      | to      |    | applicable.  |          |      |
|       | Eq      | ground  |    | Lock-out /   | Review   | 3    |
|       | uipment | pot     |    | Tag-out      | test     |      |
|       | Fault   | ential. |    | procedures   | setup.   |      |
|       |         | Test    |    | followed.    |          |      |
|       | Inad    | article |    | Operated by  |          |      |
|       | vertent | damage. |    | trained      |          |      |
|       | Contact |         |    | personnel.   |          |      |
|       | with    |         |    |              |          |      |
|       | En      |         |    | The          |          |      |
|       | ergized |         |    | electrical   |          |      |
|       | Ci      |         |    | system       |          |      |
|       | rcuits. |         |    | requires 120 |          |      |
|       |         |         |    | Volts AC and |          |      |
|       |         |         |    | has internal |          |      |
|       |         |         |    | fuses to     |          |      |
|       |         |         |    | protect each |          |      |
|       |         |         |    | individual   |          |      |
|       |         |         |    | component.   |          |      |
|       |         |         |    | The          |          |      |
|       |         |         |    | electrical   |          |      |
|       |         |         |    | system will  |          |      |
|       |         |         |    | not be in    |          |      |
|       |         |         |    | the flow     |          |      |
|       |         |         |    | path of the  |          |      |
|       |         |         |    | gas supply   |          |      |
|       |         |         |    | system.      |          |      |
+-------+---------+---------+----+--------------+----------+------+
| O     | Displ   | Death   | I  | Interior     | Verify   | Co   |
| xygen | acement | or      | /  | oxygen       | envir    | ntro |
| -Defi | of      | Brain   | C\ | monitor and  | onmental | lled |
| cient | oxygen  | Damage  | 2  | alarms part  | monitor  | R    |
| Atmos | in      | by      |    | of System    | and      | isk\ |
| phere | e       | Asphy   |    | 624 for      | alarm    | \    |
|       | nclosed | xiation |    | Bldg. 356E,  | system   | I /  |
|       | spaces  |         |    | Cell 126.    | of       | D\   |
|       | due to  |         |    |              | System   | 3    |
|       | system  |         |    | Training     | 624.\    |      |
|       | l       |         |    |              | \        |      |
|       | eakage, |         |    |              | Review   |      |
|       | o       |         |    |              | training |      |
|       | perator |         |    |              | records. |      |
|       | error,  |         |    |              |          |      |
|       | and     |         |    |              |          |      |
|       | control |         |    |              |          |      |
|       | system  |         |    |              |          |      |
|       | f       |         |    |              |          |      |
|       | ailure. |         |    |              |          |      |
+-------+---------+---------+----+--------------+----------+------+
| P     | Typical | Serious | I  | DESIGN: All  | Ind      | Co   |
| rojec | Major   | or      | /  | system       | ependent | ntro |
| tiles | Causes: | fatal   | B\ | components   | review   | lled |
| or    | Over    | injury  | 1  | rated for    | of       | R    |
| Blast | pressur | to      |    | appropriate  | system   | isk\ |
| Wave  | ization | major   |    | system MAWP. | design.  | \    |
| Ov    | of      | body    |    | Relief       | Periodic | I /  |
| erpre | various | st      |    | valves       | RV       | D\   |
| ssure | p       | ructure |    | incorporated | recerti  | 3    |
|       | ressure | and     |    | to protect   | fication |      |
|       | system  | major   |    | all system   | required |      |
|       | com     | organs. |    | components.  | by       |      |
|       | ponents | Test    |    |              | center   |      |
|       | by a    | article |    | Components   | pressure |      |
|       | variety | damage. |    | in the       | systems  |      |
|       | of      |         |    | system are   | a        |      |
|       | su      |         |    | Category D   | utomated |      |
|       | bcauses |         |    | pressure     | data     |      |
|       | (re     |         |    | system       | base.    |      |
|       | gulator |         |    | certified. A | Class 1  |      |
|       | f       |         |    | Lexan blast  | certi    |      |
|       | ailure, |         |    | wall shall   | fication |      |
|       | acc     |         |    | remain       | on all   |      |
|       | idental |         |    | between the  | systems  |      |
|       | or      |         |    | test         | before   |      |
|       | inte    |         |    | operator and | use and  |      |
|       | ntional |         |    | the test     | annual   |      |
|       | heating |         |    | setup during | recert   |      |
|       | of      |         |    | operations.\ | by       |      |
|       | co      |         |    | \            | pressure |      |
|       | ntained |         |    | \            | system   |      |
|       | g       |         |    | Pressure     | in       |      |
|       | asses/l |         |    | System       | spection |      |
|       | iquids, |         |    | Operators    | recall   |      |
|       | etc.)   |         |    | C            | system.\ |      |
|       |         |         |    | ertification | \        |      |
|       |         |         |    |              | Review   |      |
|       |         |         |    |              | Test     |      |
|       |         |         |    |              | setup    |      |
|       |         |         |    |              |          |      |
|       |         |         |    |              | Review   |      |
|       |         |         |    |              | training |      |
|       |         |         |    |              | records. |      |
+-------+---------+---------+----+--------------+----------+------+
|       | Acc     | Serious | I  | Three sensor | Eng      | Co   |
|       | idental | or      | /  | hydrogen     | ineering | ntro |
|       | Det     | fatal   | B\ | detection    | Order    | lled |
|       | onation | injury  | 1  | system       | recently | R    |
|       | or      | to      |    | within Cell  | p        | isk\ |
|       | Rapid   | major   |    | 126, Bldg.   | erformed | \    |
|       | Burning | body    |    | 356E         | to       | I /  |
|       | of      | st      |    | providing    | verify   | D\   |
|       | Unco    | ructure |    | inputs to    | envir    | 3    |
|       | ntained | and     |    | auto shut    | onmental |      |
|       | C       | major   |    | down system  | monitor  |      |
|       | hemical | organs. |    | (Refer to    | and      |      |
|       | Mi      | Test    |    | System 624   | alarm    |      |
|       | xtures. | article |    | do           | system   |      |
|       |         | damage. |    | cumentation) | of       |      |
|       |         |         |    | trips when   | System   |      |
|       |         |         |    | H2 level     | 624.\    |      |
|       |         |         |    | reaches 25%  | \        |      |
|       |         |         |    | LEL.\        | \        |      |
|       |         |         |    | \            | Ind      |      |
|       |         |         |    | Leak check   | ependent |      |
|       |         |         |    | of the test  | review   |      |
|       |         |         |    | system       | of       |      |
|       |         |         |    | performed    | system   |      |
|       |         |         |    | before       | design.  |      |
|       |         |         |    | on-reactant  |          |      |
|       |         |         |    | tests begin. | Ind      |      |
|       |         |         |    |              | ependent |      |
|       |         |         |    | Fuel Enable  | review   |      |
|       |         |         |    | switch acts  | of test  |      |
|       |         |         |    | as an        | system   |      |
|       |         |         |    | emergency    |          |      |
|       |         |         |    | stop button  |          |      |
|       |         |         |    | by           |          |      |
|       |         |         |    | d            |          |      |
|       |         |         |    | e-energizing |          |      |
|       |         |         |    | a solenoid   |          |      |
|       |         |         |    | valve and    |          |      |
|       |         |         |    | shutting off |          |      |
|       |         |         |    | the supply   |          |      |
|       |         |         |    | of reactants |          |      |
|       |         |         |    | to the fuel  |          |      |
|       |         |         |    | cell and     |          |      |
|       |         |         |    | shutting off |          |      |
|       |         |         |    | reactants    |          |      |
|       |         |         |    | from the     |          |      |
|       |         |         |    | Supply       |          |      |
|       |         |         |    | System 626.  |          |      |
+-------+---------+---------+----+--------------+----------+------+
| High  | Typical | Burning | I  | Water Deluge | Water    | Co   |
| T     | Causes: | of      | /  | system       | Deluge   | ntro |
| emper | Fire,   | c       | C\ | a            | checkout | lled |
| ature | Inte    | lothes, | 2\ | utomatically | annually | R    |
| E     | ntional | hair,   | \  | tripped with | by Fire  | isk\ |
| nviro | or      | or      | \  | increasing   | Pr       | \    |
| nment | Uninte  | flesh,  | \  | temperature  | otection | I /  |
| or    | ntional | severe  | \  | sensor in    | Speci    | D\   |
| Sur   | Heating | burns   | \  | Cell 126,    | alists.\ | 3\   |
| faces | of Test | and     | \  | Bldg. 356E   | \        | \    |
|       | Sy      | death.\ | \  | or manually  | \        | \    |
|       | stems.\ | \       | \  | from         | \        | \    |
|       | \       | \       | \  | Facility     | Review   | \    |
|       | \       | \       | \  | Control      | of       | \    |
|       | \       | \       | \  | Room.*\      | system   | \    |
|       | \       | \       | II | *\           | configu  | \    |
|       | \       | \       | /  | Ignition/    | ration.\ | \    |
|       | \       | \       | B\ | combustion   | \        | \    |
|       | \       | \       | 2  | sources      | \        | II / |
|       | \       | \       |    | minimized in | Review   | C\   |
|       | \       | \       |    | Cell 126,    | O        | 3    |
|       | Fuel    | Burning |    | Bldg. 356E.\ | perating |      |
|       | cell    | of      |    | \            | Pro      |      |
|       | related | c       |    | Caution      | cedure.\ |      |
|       | failure | lothes, |    | statement in | \        |      |
|       | from a  | hair,   |    | Procedures   | Ind      |      |
|       | variety | or      |    |              | ependent |      |
|       | of      | flesh,  |    | DESIGN:      | review   |      |
|       | sub     | severe  |    | Temperature  | of       |      |
|       | -causes | burns.  |    | sensors      | design   |      |
|       | (ind    | Test    |    | installed    | and test |      |
|       | ividual | article |    | immediately  | setup.   |      |
|       | cell    | damage. |    | upstream and |          |      |
|       | m       |         |    | downstream   |          |      |
|       | embrane |         |    | of the fuel  |          |      |
|       | f       |         |    | cell test    |          |      |
|       | ailure, |         |    | article.     |          |      |
|       | out of  |         |    | Relief       |          |      |
|       | specif  |         |    | valves       |          |      |
|       | ication |         |    | protect test |          |      |
|       | r       |         |    | article and  |          |      |
|       | eactant |         |    | test system  |          |      |
|       | pre     |         |    | from         |          |      |
|       | ssures, |         |    | overpressure |          |      |
|       | etc.).  |         |    | condition.   |          |      |
|       |         |         |    | Voltage      |          |      |
|       |         |         |    | monitoring   |          |      |
|       |         |         |    | of the fuel  |          |      |
|       |         |         |    | cell shuts   |          |      |
|       |         |         |    | off          |          |      |
|       |         |         |    | reactants in |          |      |
|       |         |         |    | the event of |          |      |
|       |         |         |    | an           |          |      |
|       |         |         |    | u            |          |      |
|       |         |         |    | nder-voltage |          |      |
|       |         |         |    | (or          |          |      |
|       |         |         |    | crossover)   |          |      |
|       |         |         |    | condition.   |          |      |
|       |         |         |    | Temperature  |          |      |
|       |         |         |    | sensors      |          |      |
|       |         |         |    | monitor fuel |          |      |
|       |         |         |    | cell fluid   |          |      |
|       |         |         |    | temperatures |          |      |
|       |         |         |    | and shut off |          |      |
|       |         |         |    | reactants in |          |      |
|       |         |         |    | the event of |          |      |
|       |         |         |    | high         |          |      |
|       |         |         |    | t            |          |      |
|       |         |         |    | emperatures. |          |      |
|       |         |         |    | (See         |          |      |
|       |         |         |    | ESTA-T-6F001 |          |      |
|       |         |         |    | for shutdown |          |      |
|       |         |         |    | criteria.)   |          |      |
+-------+---------+---------+----+--------------+----------+------+
| O     | I       | Severe  | I  | 1.Components | 1,2,     | Co   |
| xygen | gnition | Burns,  | /  | will be      | 3:Review | ntro |
| Fire  | by:     | Eq      | A\ | selected     | of       | lled |
|       | 1.Fr    | uipment | 1  | that do not  | M        | R    |
|       | iction\ | Damage, |    | actuate      | aterials | isk\ |
|       | \       | Death   |    | quickly or   | Listing  | \    |
|       | \       |         |    | have         | and      | I /  |
|       | 2.      |         |    | internal     | System   | D\   |
|       | Insuffi |         |    | movement     | Design   | 3    |
|       | ciently |         |    | that can     |          |      |
|       | com     |         |    | cause        | 4:Clean  |      |
|       | patible |         |    | frictional   | room     |      |
|       | ma      |         |    | heating.     | records. |      |
|       | terial\ |         |    |              | P        |      |
|       | \       |         |    | 2\. All      | ersonnel |      |
|       | \       |         |    | wetted       | training |      |
|       | 3.Flow  |         |    | materials    | on       |      |
|       | fr      |         |    | within the   | assembly |      |
|       | iction, |         |    | test system  | tec      |      |
|       | both    |         |    | must meet    | hniques. |      |
|       | i       |         |    | the          |          |      |
|       | nternal |         |    | requirements |          |      |
|       | and     |         |    | for oxygen   |          |      |
|       | e       |         |    | at the local |          |      |
|       | xternal |         |    | system MAWP  |          |      |
|       | flow.\  |         |    | including    |          |      |
|       | \       |         |    | lubricants   |          |      |
|       | \       |         |    | and soft     |          |      |
|       | 4.P     |         |    | goods .\     |          |      |
|       | article |         |    | 3. Flow      |          |      |
|       | impact  |         |    | velocities   |          |      |
|       |         |         |    | are kept low |          |      |
|       |         |         |    | by system    |          |      |
|       |         |         |    | design.      |          |      |
|       |         |         |    | Elimination  |          |      |
|       |         |         |    | of high      |          |      |
|       |         |         |    | pressure (\> |          |      |
|       |         |         |    | 750psig)     |          |      |
|       |         |         |    | external     |          |      |
|       |         |         |    | leak paths.  |          |      |
|       |         |         |    | Material     |          |      |
|       |         |         |    | com          |          |      |
|       |         |         |    | patibility.\ |          |      |
|       |         |         |    | 4a. All      |          |      |
|       |         |         |    | wetted       |          |      |
|       |         |         |    | surfaces     |          |      |
|       |         |         |    | will be      |          |      |
|       |         |         |    | precision    |          |      |
|       |         |         |    | cleaned for  |          |      |
|       |         |         |    | oxygen       |          |      |
|       |         |         |    | service.\    |          |      |
|       |         |         |    | 4b.During    |          |      |
|       |         |         |    | assembly     |          |      |
|       |         |         |    | components   |          |      |
|       |         |         |    | will be      |          |      |
|       |         |         |    | assembled    |          |      |
|       |         |         |    | under purge  |          |      |
|       |         |         |    | or quickly   |          |      |
|       |         |         |    | capped once  |          |      |
|       |         |         |    | removed from |          |      |
|       |         |         |    | the clean    |          |      |
|       |         |         |    | room bags to |          |      |
|       |         |         |    | prevent      |          |      |
|       |         |         |    | accumulation |          |      |
|       |         |         |    | of flammable |          |      |
|       |         |         |    | particulate  |          |      |
|       |         |         |    | in the       |          |      |
|       |         |         |    | wetted       |          |      |
|       |         |         |    | system.      |          |      |
+-------+---------+---------+----+--------------+----------+------+