Hydrogen Tube Trailer Exchange Purpose and Scope Personal Protective Equipment Tools Safety Precautions Hydrogen Pre-Travel Checks Customer Site Inspection and Precautions High Pressure H2 Tube Trailer Exchange: No Fixed (ASME) Storage Tubes or Reserve Connecting Full Hydrogen Trailer to Customer Station Disconnecting Empty Tube Trailer from Customer Station High Pressure H2 Tube Trailer Exchange with Fixed ASME Storage Tubes or Reserve Disconnecting Empty Tube Trailer from Customer Station Connecting Full Hydrogen Trailer to Customer Station Preparing the Empty Trailer for Departure Certificate and Acknowledgment of Training

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Attachment(s): Certification and Acknowledgment of Training

Author: James Aureimma 2.1 June 2011

Quality Reviewer: Guy Dalton Approver: Scoble Abrahams DEL-04-71-RNA Hydrogen Tube Trailer Exchange Copyright © The Linde Group – Distributed by a locally registered Linde company Uncontrolled Copy - do not use after date of printing

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Purpose and Scope Purpose

This chapter provides procedures and guidelines to safely deliver gaseous hydrogen product to customers by tube trailer exchange with and without fixed ASME storage systems.

Scope

This chapter covers gaseous hydrogen delivery procedures for customer installations designed for tube trailer exchange per CESSUP-23-05 : Gaseous Hydrogen Trailer Supply System Design. This chapter applies to all Linde bulk delivery drivers in North America, and contractor delivery drivers working for Linde that deliver gaseous hydrogen.

Personal Protective Equipment PPE

PPE is intended to protect the wearer while handling compressed gases during the fill process at the fill plant and during customer deliveries. For information concerning correct PPE, see IMS-27-03 : PPE User Requirements.

Body protection

Only Linde-approved clothing, consisting of a long-sleeved shirt and trousers (without cuffs) made of Nomex must be worn when handling compressed hydrogen. Arms, legs and feet must remain covered when working in the vicinity of storage vessels, pipelines or dispensing equipment containing compressed hydrogen gas. Coveralls of Nomex or equivalent flame retardant clothing are also acceptable. For suitable information on availability and upkeep, contact Cintas at 1-800-CINTAS1 or www.cintas.com (http://www.cintas.com). All clothing must meet Linde-approved standards. For more information, refer to IMS-27-03 : PPE User Requirements.

Hand protection

To prevent burns, wear approved flame retardant gloves.

Face and eye protection

Safety glasses must be worn when working within the hazard zone. The following are examples of the hazard zone:

Foot protection 2.1 June 2011

•

When decanting

•

When connecting or disconnecting trailers

•

When the driver is within six feet (two (2) metres) of pipe work or hose on a tanker or vessel during a transfer

•

When venting gas

Approved steel-toed safety boots with a leather upper and high sides must be worn when handling compressed gases. DEL-04-71-RNA Hydrogen Tube Trailer Exchange Copyright © The Linde Group – Distributed by a locally registered Linde company Uncontrolled Copy - do not use after date of printing

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Hearing protection

Hearing protection, meeting the standard for noise levels in heavy industrial areas (minimum protection rating of 27dBA), must be worn when: •

working in areas sign posted for hearing protection

•

venting gas pressure from trailers or storage vessels.

•

Two non-sparking wrenches with flat jaw surface should be used to connect the trailer to the customer hose. One wrench must have at least a 2-inch span. Suitable wrenches are:

Tools Wrenches

•

Notes

•

Maximo #112651 (Ampco W-73 12" adjustable wrench)

•

Maximo #128589 (Ampco W-1147 12" monkey wrench) Alternate: Ampco W-1148 15" monkey wrench)

Linde "Airco fitting" to CGA 1350 trailer adaptor (if required) - Maximo #314649

Distribution has a process in place to modify all existing hydrogen tube trailers with both the CGA 1350 fitting and the Linde "Airco fitting." As customer stations are upgraded to the gaseous hydrogen tube trailer standard, customer station hose ends are being changed to the CGA 1350 fitting replacing the Linde "Airco fitting." The adaptor is necessary when connecting hydrogen tube trailers without the CGA 1350 fitting to customer stations with the CGA 1350 fitting. Adaptor in place on trailer

2.1 June 2011

•

See TRO-05-01 : Adaptor Controls

•

See ALT-07-07 : Hydrogen Tube Trailer Adaptor Control Alert

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Safety Precautions Caution

•

No smoking or open flame within 25 ft. of gaseous hydrogen trailer transfer area.

•

Only operate intrinsically safe devices within 15 ft. of gaseous hydrogen trailer/transfer area. This includes cell phones, pagers and flashlights.

•

Never idle the tractor engine while the unit is connected to the hydrogen transfer area.

•

Always open and close all valves slowly.

•

To determine position of any valve, always try to close the valve.

•

Immediately cease any fill/transfer process when thunder and/or lightning is present.

•

Immediately cease any fill/transfer process when any unsafe condition is encountered.

•

Never wear man-made fibers when working with hydrogen.

•

Report any site or equipment deficiencies to your Transport Manager.

Hydrogen Pre-Travel Checks Prior to departure In addition to the standard DEL-02-09 : Pre and Post-Trip Vehicle Inspections the following checks must be done for a hydrogen tube trailer:

Step

Action

1

Confirm the trailer is full.

2

All valves on the trailer must be closed when the trailer is in transit.

3

The trailer manifold must not be under pressure in transit. Note:

Any residual pressure in the trailer manifold must be vented by use of an approved vent stack.

4

Ensure all dust plugs are in place.

5

Check and ensure the fill hose and ground straps are disconnected.

6

Check there are no audible leaks from the cylinders or from the manifold piping.

7

Check the hydrogen cylinders (tubes) have not turned in their housing. Turning of the tubes can damage the manifolds. While a slight amount of turning can be tolerated, severe turning must be reported and corrected. Refer to DEL-02-09 : Pre and Post-Trip Vehicle Inspections.

8

Check for a Purity Certificate (where required).

2.1 June 2011

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Step

Action

9

Check that the tube trailer vent stacks are secure and capped.

10

Ensure an adaptor is available before departing for a delivery.

Customer Site Inspection and Precautions Caution

Caution

2.1 June 2011

•

Follow any site specific delivery instructions. Contact the Transport Manager with any questions.

•

Note general condition of the site, including the location of emergency exits.

•

Inspect the area for trip/fall hazards.

•

Verify customer piping.

•

Inspect the site for leaks, damage, or other substandard conditions.

•

Inspect the transfer hose for leaks, damage, or other substandard conditions. Ensure hose is within the 5-year retest/replacement cycle.

•

Verify customer vent stack is free of ice, snow or any debris that could restrict flow.

•

Do not fill any vessel that does not have positive pressure verified by gauge.

•

Determine if CGA adaptor is required.

•

Inspect the fill connection and adaptor for wear or damage and recommend replacement to management if necessary.

•

Ensure trailer is grounded before beginning any operation.

•

Ensure trailer is secured and wheel chocks are installed.

•

Report any deficiencies to the Transport Manager.

All instructions are based on current CES gaseous hydrogen installation standards. Actual customer sites may differ. Always check customer piping and valve alignment before beginning any operation. Always check with customer or your Transport Manager if unusual conditions are encountered.

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High Pressure H2 Tube Trailer Exchange: No Fixed (ASME) Storage Tubes or Reserve

Procedures

Follow these procedures to perform a trailer drop and swap operation.

Connecting Full Hydrogen Trailer to Customer Station Connecting Full Hydrogen Trailer to Customer Station Step

Action

1

Position trailer in the appropriate unloading area. Note:

See TRO-15-08 : Vehicle Maneuvering.

2

Turn off the engine on the delivery vehicle and set the parking brake.

3

Install wheel chocks on the rear wheels of the delivery trailer.

2.1 June 2011

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Connecting Full Hydrogen Trailer to Customer Station Step

Action

4

Connect the ground clamp from the customer station to the trailer. Ensure secure metal to metal contact.

5

Open trailer doors.

6

Uncouple the tractor from the trailer. See DEL-03-05 : Coupling/Uncoupling Semi and Draw-Bar Trailers and DEL-03-07 : Coupling/Uncoupling Double Trailers.

7

Inspect the fill hose and trailer connections for damage. Determine if a CGA adaptor is required.

8

Connect the transfer hose to the trailer main supply valve.

9

Sweep purge the transfer hose following Steps 9.1 through 9.4.

10

2.1 June 2011

Note:

Sweep purge is the process of blowing out gross contaminants prior to cycle purging the fill hose and stanchion.

9.1

Slowly open the customer stanchion vent valve. (Do not completely open the valve, but open just enough to generate a steady flow of gas through the vent.)

9.2

Slowly open the #1 tube valve on the delivery trailer.

9.3

Slowly open the main trailer supply valve.

9.4

Allow hose to purge for 20-30 seconds, then close the customer stanchion vent valve.

Cycle purge the system following Steps 10.1 through 10.4. Note:

Cycle purge is the process of alternately pressurizing and venting a section of pipe/hose to remove contaminants and backfill the line with gas.

10.1

Close the #1 tube valve.

10.2

Open the customer stanchion vent valve, purge the system to approximately 50 psi using the pressure gauge on the trailer manifold, and then close the customer stanchion vent valve.

10.3

Open the #1 tube valve on the delivery trailer. Pressurize the system. Close the #1 tube valve.

10.4

Open the customer stanchion vent valve. Purge the system to 50 psi and then close the customer stanchion vent valve. DEL-04-71-RNA Hydrogen Tube Trailer Exchange Copyright © The Linde Group – Distributed by a locally registered Linde company Uncontrolled Copy - do not use after date of printing

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Connecting Full Hydrogen Trailer to Customer Station Step

Action Note:

Perform Steps 10.3 through 10.4 twice.

11

Open (at least) the #1 tube valve on the delivery trailer. Follow customer-specific instructions.

12

Open the customer stanchion main supply valve. Check for line pressure down stream.

13

The new trailer is now online. Open as many of the tube valves as necessary to meet customer site requirements.

Disconnecting Empty Tube Trailer from Customer Station Disconnecting Empty Tube Trailer from Customer Station Step

Action

1

Ensure trailer is grounded.

2

Ensure the customer stanchion main supply valve is closed.

3

Close all tube trailer isolation valves.

4

Slowly open customer stanchion vent valve to purge transfer hose and associated piping.

5

With trailer manifold pressure gauge reading zero, disconnect transfer hose, and reinstall the hose on the stanchion parking post.

6

Close main trailer supply valve and customer stanchion vent valve.

7

Cap the end of the trailer manifold connection.

8

Close the trailer doors.

9

Couple the tractor to the trailer. See DEL-03-05 : Coupling/Uncoupling Semi and Draw-Bar Trailers and DEL-03-07 : Coupling/Uncoupling Double Trailers.

10

Remove trailer wheel chocks.

11

Disconnect trailer ground strap.

2.1 June 2011

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High Pressure H2 Tube Trailer Exchange with Fixed ASME Storage Tubes or Reserve

Procedures

Follow the procedures below to perform an operation where the ASME tubes are used as a reserve during a trailer exchange.

Disconnecting Empty Tube Trailer from Customer Station Disconnecting Empty Tube Trailer from Customer Station Step

Action

1

Ensure trailer is grounded.

2

Place customer on reserve supply. Open reserve isolation valve(s).

3

Isolate empty trailer by closing customer stanchion main supply valve.

4

Close all trailer tube valves.

5

Slowly open customer stanchion vent valve to purge transfer hose and associated piping.

6

With trailer manifold pressure gauge reading zero, disconnect transfer hose and reinstall the hose on the stanchion parking post.

7

Close main trailer supply valve and customer stanchion vent valve.

8

Cap the end of the trailer manifold connection.

9

Close the trailer doors.

10

Couple the tractor to the trailer. See DEL-03-05 : Coupling/Uncoupling Semi and Draw-Bar Trailers and DEL-03-07 : Coupling/Uncoupling Double Trailers.

2.1 June 2011

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Disconnecting Empty Tube Trailer from Customer Station Step

Action

11

Remove trailer wheel chocks.

12

Disconnect trailer ground clamp.

Connecting Full Hydrogen Trailer to Customer Station Connecting Full Hydrogen Trailer to Customer Station Step

Action

1

Position trailer in the appropriate unloading area. Note:

See TRO-15-08 : Vehicle Maneuvering.

2

Turn off the engine on the delivery vehicle and set the parking brake.

3

Install wheel chocks on the rear wheels of the delivery trailer.

4

Connect the ground clamp from the customer station to the trailer. Ensure secure metal to metal contact.

5

Open trailer doors.

6

Uncouple the tractor from the trailer. See DEL-03-05 : Coupling/Uncoupling Semi and Draw-Bar Trailers and DEL-03-07 : Coupling/Uncoupling Double Trailers.

7

Determine if CGA adapter is required.

8

Connect the transfer hose to the trailer main supply valve.

9

Sweep Purge the transfer hose by following Steps 9.1 through 9.4.

10

9.1

Open customer stanchion vent valve. (Do not completely open the valve, but open just enough to generate a steady flow of gas through the vent.)

9.2

Slowly open the #1 tube valve on the delivery trailer.

9.3

Slowly open the main trailer supply valve.

9.4

Allow hose to purge for 20-30 seconds, then close customer stanchion vent valve.

Cycle purge the system by following Steps 10.1 through 10.4. 10.1

Close the #1 tube valve on the delivery trailer.

10.2

Open the stanchion vent valve, purge the system to 50 psi and then close the customer stanchion vent valve.

10.3

Open the #1 tube valve on the delivery trailer. Pressurize the system. Close the #1 tube valve.

10.4

Open the customer stanchion vent valve. Purge the system to 50 psi and then close the customer stanchion vent valve. Note:

Perform Steps 10.3 through 10.4 twice.

11

Open (at least) the #1 tube valve on the delivery trailer.

12

Slowly open the customer stanchion main supply valve. Check for line pressure down stream.

2.1 June 2011

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Connecting Full Hydrogen Trailer to Customer Station Step

Action

13

Refill the ASME tube storage. Carefully monitor the fill process. If tubes are at or below the minimum refill setpoint, then proceed with bumping the reserve ASME tubes to normal operating pressure. Maximum ASME tube pressure, fill pressure and reorder point are posted at the site. Slowly pressurize the ASME tube bundle one cylinder at a time until the maximum fill limit is reached. Open additional trailer tube valves one at a time as necessary to fill/equalize the reserve supply with the full trailer. Verify adequate pressure in the reserve ASME tube bank for the next trailer exchange. Close the reserve isolation valve when filling is completed. Notes: 1.

Only ASME tubes (used as reserve) may be refilled. Individual DOT cylinders or groups of cylinders as part of a manifolded system must not be refilled. These cylinders are the responsibility of the customer to have refilled or replaced by the supplier.

2.

ASME tube fill limits:

ASME tubes used by Linde are rated at 2450 psig or 2800 psig. The following fill limits must be adhered to when bumping ASME tubes:

2.1 June 2011

ASME tube rated pressure (psig)

ASME tube rated pressure (psig)

2450

2450

2800

2800

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Connecting Full Hydrogen Trailer to Customer Station Step

Action ASME Tube with Maximum Allowable Working Pressure (MAWP) Circled

14

Open as many of the tube valves as necessary to meet customer site requirements.

Preparing the Empty Trailer for Departure Procedure

Follow this procedure when preparing an empty trailer for departure.

Step

Action

1

Ensure all tube trailer valves are closed.

2

Ensure the trailer manifold is not under pressure.

3

Ensure there are no leaks from the customer storage facility or the trailer.

4

Ensure all tools are collected.

5

Complete all necessary paperwork.

2.1 June 2011

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Certificate and Acknowledgment of Training Gaseous hydrogen tube trailers

2.1 June 2011

The Certification and Acknowledgment of Training (see attachment) confirms the driver has obtained a complete understanding of product handling and safe handling of trailers and equipment for gaseous hydrogen tube trailers.

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