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SYSTEM/SUBSYSTEM SPECIFICATION (SSS)
FOR THE
NEW MEXICO HYDROGEN PRODUCTION AND DISPENSING
DEMONSTRATION
1 February 2005
Prepared by:
U.S. Army National Automotive Center (NAC)
in conjunction with the
New Mexico Hydrogen Technology Partnership (HyTep)
Authenticated by: ________________________ Approved by: _______________________
U.S. Army NAC
HyTeP Program
Manager
Distribution Statement "D" - Distribution authorized to Department of Defense (DoD) and DoD
contractors for administrative or operational use determined 23 July 1991. Other requests for a
copy of this document shall be referred to OO-ALC/YW.
WARNING - This document contains technical data whose export is restricted by the Arms Export
Control Act (Title 22, U.S.C., Sec 2751 et seq.) or Executive Order 12470. Violations of these
export haws are subject to severe criminal penalties.
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1.0
SCOPE
1.1
IDENTIFICATION
Title: New Mexico Hydrogen Production and Dispensing Demonstration
Abbreviated Title: N/A
1.2
SYSTEM OVERVIEW
The New Mexico Hydrogen Technology Partnership (HyTeP), in collaboration with federal,
state and local government agencies is developing a hydrogen production, storage and
dispensing facility located at the site of an existing Compressed Natural Gas (CNG) refueling
station located at the Albuquerque International Sunport. Hydrogen will be produced
through the reformation of natural gas available at the target site. Produced hydrogen will be
stored and dispensed as hydrogen and hydrogen blended with natural gas (HCNG) and both
dispensed as fuels in support of internal combustion engine vehicles.
Statement of Operational Need
This system will serve as a prototype hydrogen infrastructure, which will aid problem
resolution and planning for the implementation of a hydrogen economy. The primary
objective for developing a hydrogen infrastructure is to support objectives for reducing our
nation’s dependence on foreign oil. Additionally, implementation of hydrogen fueling
technologies will support reduced emissions for a wide range of air pollutants, including
carbon dioxide, which is linked to impacts on world-wide climate change.
The project will displace imported oil with domestically produced fuels and reduce emissions
of a wide range of air pollutants, including carbon dioxide linked to climate change impacts.
Future phases of the project will seek to produce hydrogen cost effectively from renewable
resources, such as biomass, solar and wind, and to use the hydrogen in advanced fuel cells to
generate electricity for transportation and stationary source applications.
Project performance at the Albuquerque Sunport will provide New Mexico with the unique
opportunity to lead the nation with regard to the establishment and sustainment of a hydrogen
infrastructure. This leadership is expected to continue, resulting in the retention of locally
related jobs and in the development of technology related employment throughout the state.
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1.3
DOCUMENT OVERVIEW
The purpose of the New Mexico Hydrogen Production and Dispensing Demonstration
System/Subsystem Specification (SSS) is to establish system level requirements for all
hardware and software systems associated with the New Mexico Hydrogen Facility.
Requirements specified within this document will be traceable to the system design and will
be utilized in the development of system qualification tests; which will be developed to
specifically validate that each stated requirement has been achieved through system design,
build, and implementation.
2.0
REFERENCED DOCUMENTS
The following documents (Figure 2-1) of the exact issue shown form a part of this
specification to the extent specified herein. In the event of conflict between the documents
referenced herein and the contents of this specification, the contents of this specification shall
be considered a superseding requirement.
Doc No.
1
2
3
Figure 2-1 -- Referenced Documents
Title
NFPA 70
NFPA 50A
ASME Code B31.3
3.0
ENGINEERING REQUIREMENTS
Alternative systems may be submitted; however, HyTeP may or may not elect to review
and/or select such proposals at its sole discretion. Any submissions not conforming to the
requirements stated in this specification shall list all items which are non-conforming.
The system shall meet all requirements stated in this specification unless otherwise
agreed to by HyTeP.
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3.1
SYSTEM CAPABILITY
This section is divided into subparagraphs to itemize the requirements associated with each
capability of the New Mexico Hydrogen Production and Dispensing Demonstration. A
"capability" is defined as a group of related requirements. The word "capability" may be
replaced with "function," "subject," "object," or other term useful for presenting
requirements. Subparagraphs found within this section identify a required system capability
and itemize the requirements associated with the capability. If the capability can be more
clearly specified by dividing it into constituent capabilities, the constituent capabilities are
provided in subparagraphs and/or bullets. The following capability shall be provided:
3.1.1 Facility Siting and Permits
The New Mexico Hydrogen Production and Dispensing System shall provide for the
following siting and permitting requirements:
a) The system shall be designed in compliance with local construction permitting and
shall achieve and retain Fire Marshall approval in association with design and
operational aspects.
b) System design and implementation shall comply with airport security regulations and
requirements as imposed by the federal government.
c) The system and associated facilities shall comply with all zoning requirements.
3.1.2 Hydrogen Production, Storage and Dispensing
The New Mexico hydrogen production, storage and dispensing system shall provide for the
following production, storage and dispensing capabilities:
a) The system shall reform natural gas to produce hydrogen to 99.999% to allow dispensing
of compressed hydrogen at 5,000 psi or blended hydrogen and compressed natural gas
(HCNG-blend containing up to 30% hydrogen by volume) at 3,600 psi and interface with
current on-board hydrogen storage systems within internal combustion engine vehicles
and to support fuel cell vehicles and stationary fuel cells in future phases of the project.
1. System shall ensure compatibility with multiple hydrogen sources (biomass,
solar/wind electrolysis) in future phases of the project.
2. System’s shall meet the Department of Energy’s hydrogen cost target of $3/gge
or $3/kg.
b) The system shall provide for on-site compression and storage of hydrogen.
c) The system shall be capable of dispensing hydrogen and HCNG for a minimum of three
light-duty internal combustion engine vehicles, per day with the ability to increase
production to provide hydrogen and HCNG for six vehicles per day.
d) The system shall have the capability to fast-fuel a minimum of three light duty vehicles,
back to back without loss of pressure or delay.
e) The system shall provide for card-activated, automated dispensing of hydrogen and
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HCNG to vehicles by trained and approved users. The system shall be fully capable of
automated start-up and control and a turndown ratio of atleast 4:1.
f) The hydrogen and HCNG system should not interfere with ongoing CNG vehicle filling
schedules.
3.1.3 Hydrogen Facility Security and Safety
The New Mexico hydrogen production, storage and dispensing system shall provide for the
following security and safety capabilities:
a) The system shall comply with local and federal government fire and safety
codes/standards.
b) System design and implementation shall comply with airport security regulations and
requirements as imposed by the federal government.
c) Nitrogen purge point shall be strategically designed into the system to adequately provide
for safe operation and maintenance.
d) Since hydrogen fires are invisible, the entire equipment room containing the hydrogen
system shall be designed as a controlled area, accessible only to those who are trained
and certified with regard to this technology.
e) Security/Safety systems shall continuously scan for infrared and ultraviolet radiation,
both of which are typical signatures of a hydrogen flame.
f) Combustible gas monitors shall be used to monitor hydrogen in work areas. These
monitors shall signify an alarm at 25% Lower Flammability Limit (LFL) of hydrogen.
g) The system shall provide an emergency shutdown that shall enable a complete system
shutdown automatically or manually. This shutdown shall provide an alarm and
annunciation visually and audibly to indicate that a shutdown has been initiated.
h) If the hydrogen system isolation is breached, as detected by IR (infra-red) and UV
(ultraviolet) scanners, gas detectors, or human intervention, the second contingency of
isolation is automatically initiated by isolating all hydrogen storage, hydrogen
production, and hydrogen dispensing; and by shutting off the power supply to the
generator, dryer, and compressor.
i) The hydrogen electrical system within the gas building shall be engineered as Class 1,
Division 2, in accordance with National Fire Protection Code (NFPA) 70.
j) The systems hydrogen storage and related piping/tubing shall comply with NFPA 50A
and American Society of Mechanical Engineers (ASME) Code B31.3.
k) Additional safety measures may include: 1) Vent stack temperature monitors, 2) Alarm
horns, and strobe lights, 3) System calibration and testing, 4) Vent stack fire suppression.
l) In the event of a hydrogen event, the system shall isolate sections of the system and shut
off the power to all operating equipment.
m) Fluid lines shall be color coded in accordance with the following:
 Safe colors: white, black
 Danger/fuel: blue (sky, dark), red, yellow
 Inert gas: orange
n) The gas building shall be protected with a fuse-link-type fire sprinkler system.
o) The system’s vent stack shall have a helium purge system for extinguishing any extensive
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fires that may develop in the vent stack. A thermocouple installed at the top (exit) of the
vent stack shall trigger an alarm condition if exit gas temperatures reach 250ºF. The
system shall provide for the release of helium into the vent stack as a manually initiated
operation.
3.2
SYSTEM EXTERNAL INTERFACE REQUIREMENTS
3.2.1 Fueling Systems and Hydrogen Vehicles/Platforms
The New Mexico Hydrogen Production and Dispensing System shall have the capability to
interface and to refuel the following types of alternative fuel vehicles, which utilize hydrogen
fuels/fuel blends:
a) Hydrogen and HCNG dispensed to converted internal combustion engine (ICE)
vehicles.
b) Hydrogen and HCNG dispensed to converted Hybrid-Electric Vehicles.
c) Hydrogen and HCNG dispensed to fixed platforms via transport
mechanism (i.e., fixed site and/or transportable Auxiliary Power Units
(APUs).
d) Hydrogen and HCNG dispensing to local airport ground vehicles utilized for
baggage, forklift, towing, etc. The capability shall be provided to allow for the transport
of hydrogen and the refueling of such vehicles.
3.3
SYSTEM INTERNAL INTERFACE REQUIREMENTS
3.3.1 Hydrogen and CNG Systems
The Hydrogen component of the system shall interface with existing CNG systems to the
extent that common use of facilities, structures, and safety measures are fully integrated. The
CNG system is operated and maintained by Clean Energy Fuels. Additional interface
requirements shall include:
a) Access to CNG systems shall not be inhibited or restricted beyond current use
restrictions
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3.4
SYSTEM INTERNAL DATA REQUIREMENTS
3.4.1 Operational Support Data
The system shall provide safety information for first time users and shall require that user
identification be retained within the system; allowing only trained and approved users to
perform refueling functions. Additional related requirements include:
a) Training data shall be provided at the pump and shall require user
acknowledgement of safety related data prior to system utilization.
b) The system shall provide self diagnostics for safety related functions and shall
log system shut downs for subsequent analysis.
c) Significant safety/security failures such as fire, emissions, and critical system
failures shall automatically notify emergency responders. All related manual
system shutdowns shall thereafter be logged in order to support post-event
analysis.
d) The system shall log performance parameters such as kilograms of hydrogen
produced daily, the quantity of hydrogen dispensed daily, failed attempts to
refuel due to unavailable fuel, failed attempts to refuel due to system failure,
failed attempts to refuel due to probable user error, and failed attempts to refuel
due to suspect security/safety violations.
e) System shall be remotely monitored 24 hr/day and have remote system control
capability.
f) System shall not require specialized on-site personnel for normal operation and
vehicle refueling.
g) Data collection strategy shall be described including capability for automated
personal computer interface.
3.5
SYSTEM SECURITY AND PRIVACY REQUIREMENTS
3.5.1 Security Classification
The New Mexico Hydrogen Production and Dispensing System is unclassified and all
components, following system qualification testing, will become the property of the City of
Albuquerque.
3.5.2 Privacy Act
The New Mexico Hydrogen Production and Dispensing System will not retain any data
requiring protection under the Privacy Act.
3.5.3 Facility and System Access
Facility access shall include current restrictions and shall not allow use of dispensing
facilities without specific user recognition via card and pin number entry.
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System users shall be restricted based upon prior authorization and only following receipt
and acknowledgement of appropriate training.
3.6
SYSTEM QUALITY FACTORS
Quality Assurance practices shall be imposed as described within the associated Program
Management Plan (PMP). Subordinate paragraphs specify system requirements pertaining to
SunPort Hydrogen Dispensing System Quality Factors.
3.6.1 System Functionality
The New Mexico Hydrogen Production and Dispensing System shall provide the capability
to perform all functions listed within Section 3.0 of the SSS.
3.6.2 System Testability
The system shall provide the capability to be tested within a test environment that is
equivalent to the environment in which the System will perform.
3.6.3 System Usability
The system shall perform in a manner similar to CNG dispensing. System displays shall
be understood and system usage shall be menu driven where practical.
3.7
DESIGN AND CONSTRUCTION CONSTRAINTS
New Mexico Hydrogen Production and Dispensing System hardware/software design and
construction constraints, including physical constraints, shall be provided for as follows:
a)
b)
c)
d)
3.8
The System hardware shall consist of commercial-off-the-shelf (COTS) equipment
where practical.
Target location shall be the CNG refueling station at Albuquerque Sunport
The system shall be designed in a modular fashion and shall allow for a
straightforward and economical expansion of hydrogen production; including
associated storage.
The system design shall not limit the future production of hydrogen from renewable
resources, such as biomass solar and wind; and to use advances hydrogen fuel cells
to generate electricity for transportation and stationary applications.
LOGISTICS RELATED REQUIREMENTS
Subordinate paragraphs specify system requirements providing for logistics considerations.
Considerations include, but are not limited to: system maintenance, hardware/software
support/sustainment, warrantees, and existing facilities, and equipment.
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3.8.1 Logistics Supportability
The System shall comply with the following logistics related requirements impacting system
sustainment/supportability:
a)
b)
c)
d)
e)
f)
g)
The System shall provide the capability to be economically maintained; sustaining
operations for a minimum of 5 years.
The system design shall provide easy maintenance/repair access to all
subsystems/components having higher failure rates.
The system design shall provide for the utilization of common components and a
listing of system alternatives for system consumables and components/subsystems
requiring periodic replacement.
The system shall be designed in support of program phases as described within the
PMP; facilitating future updates as dictated by Phases 2 through 5.
The system shall be comprised of standardized components where practical and
placed under configuration management in order for optimum performance and
sustainment objectives to be achieved.
Standard/common hardware shall be delivered with a five-year, on-site parts and
labor warranty.
System components/subsystems shall be selected from hardware/software
components that can be easily procured within 72 hours. Allowable longer lead
times are allowed for replacement of the following components;/subsystems.
3.8.2 Integrated Logistics/Diagnostics Capability
The System design shall strive to be supportable through the application of integrated
logistics support concepts and shall therefore provide an integrated diagnostics capability.
Diagnostics capabilities shall include:
a)
b)
c)
d)
The system shall provide self-diagnostics for safety related functions and shall log
system shut downs for subsequently analysis.
All systems critical to system performance and safety shall be monitored through
self-diagnostics to identify degraded system performance and to isolate
system/subsystem failures critical to continued system operation.
The system shall provide a system diagnostics report upon user request. This report
shall provide diagnostics for all critical systems sufficient to allow
maintenance/repair technicians to locate and respond to system failures.
The system shall be remotely monitored by qualified personnel on a continuous
basis.
4.0
QUALIFICATION PROVISIONS
4.1
QUALIFICATION METHODS
To ensure that the requirements in Section 3.0 have been satisfied, the following
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Qualification Methods shall be applied.
a)
Demonstration: The operation of the system (or subsystem) that relies on
observable functional operation not requiring the use of elaborate instrumentation
or special test equipment.
b)
Analysis: The processing of accumulated data obtained from other qualification
methods. Examples are interpretation or extrapolation of test data.
c)
Inspection: The visual examination of system code, documentation, etc.
4.2
NOTES
4.3
DEFINITIONS
Metrics: Measurement tools used for the assessing the qualitative and quantitative progress
of development with respect to the development standards specified.
Objective: A statement that specifies precisely what behavior is to be exhibited, the
conditions under which behavior will be accomplished, and the minimum standard of
performance. Objectives describe only the behaviors that directly lead to or specifically
satisfy a job performance requirement. An objective is a statement of instructional intent.
Subject Matter Expert (SME): A person who has high-level knowledge and skill in the
performance of a job.
5.0
ACRONYMS AND ABBREVIATIONS
AFB
Air Force Base
CLS
CMI
Contractor Logistics Support
Computer-Managed Instruction
DoD
Department of Defense
SDD
SSS
TBD
Software Design Description
System Segment Specification
To Be Determined
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EXISTING SUNPORT CNG SITE ENGINEERING DESIGN
ATTACHMENT I
(see CNG site AutoCAD Drawing included as separate file)
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PROJECT MANAGEMENT PLAN (PMP)
ATTACHMENT II
(see PMP included as separate file)
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