A global power equipment manufacturer required a specialized facility for safely testing hydrogen fuel cells and batteries. Their existing facility did not have a hydrogen fuel cell lab or the capabilities to safely test given the complexities of hydrogen. They needed a dedicated space for robust hydrogen fuel cell system testing.
The company operates in a leased building and planned to install a new test cell there. It independently purchased AVL equipment for fuel cell testing and battery testing, along with a bulk hydrogen storage system. However, the existing leased space required significant modifications to accommodate the safe hydrogen fuel cell system testing and battery testing. The vision included a dedicated area for advancing their hydrogen fuel cell designs.
The facility lacked the reinforcement necessary to contain a potential hydrogen explosion or equipment to detect a hydrogen leak or fire. Nor was there any place to safely store the batteries. Being a leased space introduced layers of complexity and constraints in designing and constructing the hydrogen fuel cell lab, particularly for secure hydrogen fuel cell designs. This highlighted the critical need for an integrated approach to hydrogen fuel cell system testing.
ACS was responsible for the design of the hydrogen lab fuel cell and battery test cell, including the hydrogen distribution system, battery storage, and an explosion relief wall. The ACS team also designed and fabricated a Programmable Logic Controller (PLC) system that consisted of five panels controlling the hydrogen delivery, hydrogen fuel cell system testing, and safety systems, and providing user interface points for the operators. This comprehensive solution facilitated the safe development of new hydrogen fuel cell designs.
To reinforce the leased hydrogen fuel cell lab workspace while keeping hydrogen safety hazards and precautions in mind, the ACS design involved replacing the floor of the existing building and adding a reinforced Concrete Masonry Unit (CMU) block structure inside the building to contain the test cell.
The ACS engineers designed this inner structure to include an explosion relief wall. The leased space has a large parking lot that abuts a freeway. The lot is close enough that flying panels from the wall might reach the parking lot or freeway if an event occurred. ACS partnered with BakerRisk, a firm that specializes in explosion-related design and analysis, to provide a design and structural specifications for the relief wall. ACS procured the long lead materials to expedite the build process, ensuring the safety of future hydrogen fuel cell designs.
Using this design, specifications, and materials, the owner’s general contractor installed the custom explosion relief wall system. The heavy weight of the panels would limit how far they could get thrown. To further control the scope of a potential debris field, heavy cables tether the panels, allowing them to blow out during an explosion contained to a defined area. This custom design helps mitigate the risk of the explosion causing damage or harm beyond the immediate facility.
The building’s existing workspace was deemed unsafe and not large enough to test or store batteries. The ACS team designed an external battery storage room that shares a wall and a connecting door with the company’s leased area within the building. As part of the overall hydrogen safety system designed by ACS, the storage area features a recirculating water system to manage potential thermal runaway events within the battery room. A sump below the grated floor captures and recirculates sprinkler water to avoid flooding.
ACS teams designed, fabricated, and integrated a PLC system with five panels containing a PLC, Remote Input/Output (RIO) hardware, and three Human-Machine Interface (HMI) points. This system controls hydrogen delivery, hydrogen fuel cell system testing, and safety systems. The safety PLC is responsible for both process control and safety systems, using a combination of RIO hardware to monitor elements based on predefined setpoints and safety states, including:
The safety PLC integrates with the building’s fire detection and safety systems for emergency shutdowns and hydrogen line purging.
The other PLC systems, integrated with the safety PLC, control:
The integration of the PLC systems with facility systems and the test cell allows for efficient test running, setpoint monitoring, and safe shutdowns when necessary.
To ensure safety and prevent unwanted events, ACS paid special attention to material specification to avoid pitfalls common with hydrogen testing. One example of this is the use of 316L stainless steel for the hydrogen distribution to avoid hydrogen embrittlement. Other complexities include leak checking the installed distribution system with helium. The PLC systems were designed to meet stringent hydrogen safety hazards and precautions, creating a fully integrated and secure hydrogen test environment within the constraints of the leased facility.
The hydrogen lab test cell was successfully built and commissioned according to ACS’ design, allowing the manufacturer to test hydrogen fuel cells, batteries, and integrated powertrain components in one facility.
The ACS design for modifications to the leased facility incorporated advanced safety features like the explosion relief wall and specialized battery storage. ACS’ integrated PLC system ensures precise control over hydrogen delivery, test operations, and safety procedures.
ACS project managers provided construction administration services, addressing the complexities of working within a leased building and facilitating smooth coordination between various stakeholders to ensure the project’s success.
With the new hydrogen fuel cell lab testing cell, the company has been able to expand their testing capabilities in a secure, controlled environment. It also now has a flexible platform adaptable to future needs.