Animation of a Hydrogen Fueling Station Example Layout (Text Version)

Below is a text version of an animation that provides an example of a typical hydrogen fueling station layout along with some of the setback requirements, codes, and standards that govern the design, construction, and operation of such a station.

The animation is a map-like drawing of an example hydrogen fueling station. A food market and two parking lots are located in the upper-right corner of the lot. A car wash, a parking lot, and a trash enclosure are located on the left side of the lot. A fuel-dispensing island with a canopy is located in the bottom-right corner of the lot. A secondary street is located along the right side of the lot, and a primary street is located along the bottom of the lot.

Setback distances are indicated by colored regions and are summarized in a setback table titled "2010 National Fire Protection Association (NFPA) Setbacks":

  • NFPA 55, Table 11.3.2.2 – Minimum distance from liquefied hydrogen systems to exposures:
    • Walls adjacent to system constructed of combustible material (1,500 liter liquid hydrogen storage tank) – 50-foot setback
  • NFPA 55, Table 11.3.2.2.1(a) – Minimum distance from outdoor gaseous hydrogen systems to exposures:
    • Air intake openings – 30-foot setback
    • Wall openings – 30-foot setback
    • Lot line – 30-foot setback
    • Parked vehicles – 15-foot setback
    • Building (with combustible walls) – 10-foot setback
  • NFPA 52, Table 9.3.1.4 – Separation distances for outdoor gaseous hydrogen dispensing systems:
    • Building, line of adjoining property that can be built on, any source of ignition (only pertains to dispersing equipment) – 10-foot setback
    • Nearest public street or public sidewalk (only pertains to dispersing equipment) – 10-foot setback
    • Storage containers (only pertains to dispersing equipment) – 3-foot setback

Setbacks are applicable to a 7,000 psi hydrogen system.

The animation links to construction approval codes and operation approval codes.

View the layout animation.

While the setback information in this animation is based on 2010 National Fire Protection Association requirements, other federal, state, and local requirements may apply. Learn more about hydrogen fueling stations.

Construction Approval Codes

The animation lists the following construction approval codes.

ASME B31.3, Process Piping (American Society of Mechanical Engineers, 2006)

  • F323.4(5) Specific Material Considerations-Metals
  • IX K305 Pipe
  • IX K306 Fittings, Bends, and Branch Connections
  • IX K307 Valves and Specialty Components

CGA G-5.4, Standard for Hydrogen Piping Systems at Consumer Locations (Compressed Gas Association, 2005)

  • 3.0 Piping System Criteria
  • 3.1 General
  • 3.2 Piping Materials
  • 3.3.2 Isolation Valves
  • 3.3.3 Emergency Isolation Valves
  • 3.3.4 Excess Flow Valves
  • 3.3.5 Check Valves
  • 3.3.7 Gasket and Sealing Materials
  • 3.3.8 Additional Requirements
  • 5.0 Installation
  • 5.1 Installation General
  • 5.1 Piping Installation General
  • 5.2 Piping Installation Above Ground Installation
  • 5.3 Piping Installation Underground Installation

CGA G-5.5, Hydrogen Vent Systems (Compressed Gas Association, 2004)

  • 6.0 Vent System
  • 6.2 Sizing
  • 6.3 Design
  • 6.4 Materials
  • 6.5 Components
  • 7 Installation
  • 9 Maintenance

CGA P-1, Safe Handling of Compressed Gases in Containers (Compressed Gas Association, 2006)

  • 4.1 Transportation Regulating Authorities
  • 4.2 Container Regulations
  • 4.3 Container Filling Regulations
  • 4.4 Regulating Authorities of Employee Safety and Health
  • 6.2 Flammable Gases

CGA PS-20, Direct Burial of Gaseous Hydrogen Storage Tanks (Compressed Gas Association, 2006)

CGA PS-21, Adjacent Storage of Compressed Hydrogen and Other Flammable Gases (Compressed Gas Association, 2005)

CGA S-1.3, PRD Standards Part 3 - Stationary Storage Containers for Compressed Gases (Compressed Gas Association, 2005)

  • 5.3.2 Nonliquid Compressed Gases
  • International Fire Code (International Code Council, 2009)
  • 404 Fire Safety and Evacuation Plan
  • 406 Employee Training and Response Procedures
  • 407 Hazard Communication
  • 906 Portable Fire Extinguishers
  • 907 Fire Alarm and Detection Systems
  • 911 Explosion Control
  • 2201 Scope
  • 2201.1 Scope
  • 2201.5 Electrical
  • 2204 Dispensing Operations
  • 2204.3.5 Emergency Procedures
  • 2205.4 Sources of Ignition
  • 2209.2 Equipment
  • 2209.2.1 Approved Equipment
  • 2209.2.3 Electrical Equipment
  • 2209.3 Location on Property
  • 2209.3.1 Separation from Outdoor Exposure Hazards
  • 2209.3.2.3 Indoors
  • 2209.3.2.6 Canopy Tops
  • 2209.3.3 Canopies
  • 2209.4 Dispensing into Motor Vehicles at Self-Service Hydrogen Motor Fuel-Dispensing Facilities
  • 2209.5 Safety Precautions
  • 2209.5.2 Emergency Shutoff Valves
  • 2209.5.2.1 Identification
  • 2209.5.3.1 System Requirements
  • 2209.5.4 Venting of Hydrogen Systems
  • 2209.5.4.2 Pressure Relief Devices
  • 2209.5.4.2.1 Minimum Rate of Discharge
  • 2211.3.1 Equipment
  • 2211.7 Repair Garages for Vehicles Fueled by Lighter-than-Air Fuels
  • 2211.8 Defueling of Hydrogen from Motor Vehicle Fuel Storage Containers
  • 2211.8.1.2 Atmospheric Venting of Hydrogen from Motor Vehicle Fuel Storage Containers
  • 2211.8.1.2.4 Grounding and bonding
  • 2703.2.1 Design and Construction of Containers, Cylinders, and Tanks
  • 2703.2.2 Piping, Tubing, Valves, and Fittings
  • 2703.9.3 Protection from Vehicles
  • 2703.9.4 Electrical Wiring and Equipment
  • 2703.10.1 Valve Protection
  • 2705 Use, Dispensing, and Handling
  • 2705.1.10 Liquid Transfer
  • 3003 General Requirements
  • 3003.2 Design and Construction
  • 3003.3 Pressure Relief Devices
  • 3003.6 Valve Protection
  • 3003.8 Wiring and Equipment
  • 3003.16.8 Connections
  • 3003.16.14 Classified Areas
  • 3005.3 Piping Systems
  • 3005.4 Valves
  • 3005.5 Venting
  • 3005.7 Transfer
  • 3203.1.3 Foundations and Supports
  • 3203.2 Pressure Relief Devices
  • 3203.2.2 Vessels or Equipment Other than Containers
  • 3203.2.6 Shutoffs Between Pressure Relief Devices and Containers
  • 3203.3 Pressure Relief Vent Piping
  • 3203.5.3 Securing of Vaporizers
  • 3203.5.4 Physical Protection
  • 3203.7 Electrical Wiring and Equipment
  • 3203.8 Service and Repair
  • 3204.4.5 Venting of Underground Tanks
  • 3205.1.2 Piping Systems
  • 3205.1.2.3.2 Shutoff Valves on Piping
  • 3205.3.2 Emergency Shutoff Valves
  • 3501.1 Scope
  • 3503 General Requirements
  • 3503.1.2 Storage Containers
  • 3503.1.3 Emergency Shutoff
  • 3503.1.5.1 Bonding of Electrically Conductive Materials and Equipment
  • 3504 Storage
  • 3505 Use

International Fuel Gas Code (International Code Council, 2009)

  • 101.2.1 Gaseous Hydrogen Systems
  • 703.3 Pressure Relief Devices
  • 703.4 Venting
  • 704 Piping, Use, and Handling
  • 705 Testing of Hydrogen Piping Systems
  • 706.3 Outdoor Gaseous Hydrogen Systems
  • 708 Design of Liquefied Hydrogen Systems Associated with Hydrogen Vaporization Operations

NFPA 30A, Code for Motor Fuel Dispensing Facilities and Repair Garages (National Fire Protection Association, 2003)

  • 6.7 Emergency Electrical Disconnects
  • 8 Electrical Installations
  • 9.2.2 Tank Filling and Bulk Delivery
  • 9.4 Operating Requirements for Attended Self-Service Motor Fuel Dispensing Facilities
  • 9.5 Operating Requirements for Unattended Self-Service Motor Fuel Dispensing Facilities

NFPA 52, Vehicular Fuel Systems Code (National Fire Protection Association, 2010)

  • 5.3 Design and Construction of Containers, Cylinders, and Tanks
  • 5.4 Pressure Relief Devices
  • 5.5 Vent Pipe Termination
  • 5.6 Pressure Gauges
  • 5.7 Pressure Regulators
  • 5.8 Fuel Lines
  • 5.9 Valves
  • 5.10 Hose and Hose Connections
  • 5.11 Vehicle Fueling Connection
  • 9.2 General System Requirements
  • 9.2.3 Equipment Security and Vehicle Protection
  • 9.2.4 Out of Service Bulk Storage
  • 9.2.5 Equipment Security and Vehicle Protection
  • 9.2.6 Cargo Transport Unloading
  • 9.2.7 Control Device Icing
  • 9.2.8 Vehicle Ignition Classification
  • 9.2.9 Fueling Connection Leak Prevention
  • 9.2.10 Compression and Processing Equipment
  • 9.2.11 Reference to NFPA 37 for Compressor Installations
  • 9.2.12 Electrical Classification for Compressors
  • 9.2.13 Liquid Carryover Prevention
  • 9.2.14 Detection for Dispensing Equipment
  • 9.2.15 General System Requirements
  • 9.2.16 General System Requirements
  • 9.3 System Siting
  • 9.3.1 General
  • 9.3.1.3 General
  • 9.3.2.3 Outdoors
  • 9.3.3 Indoors
  • 9.3.3.12 Warning Signs
  • 9.3.3.3 Indoors
  • 9.6 Installation of PRDs on Fueling Systems
  • 9.7 Installation of Pressure Gauges
  • 9.9 Installation of Piping and Hoses
  • 9.11 Installation of Emergency Shutdown Equipment
  • 9.12 Installation of Electrical Equipment
  • 9.13 Stray or Impressed Currents and Bonding
  • 9.14 System Operation
  • 9.15 Fire Protection
  • 14.2.4 Indoor Fueling
  • 14.4.3 Liquid Hydrogen Vehicle Dispensing Systems
  • 14.8 Pressure Relief Devices

NFPA 55, Compressed Gases and Cryogenic Fluids Code (National Fire Protection Association, 2010)

  • 4 General Requirements
  • 6.12 Hazard Identification Signs
  • 7.1.2.5 Pressure-Relief Devices
  • 7.1.4 Security
  • 7.1.6 Separation from Hazardous Conditions
  • 7.3.1.10 Use and Handling
  • 10.2.1 Pressure-Relief Devices
  • 10.2.2 Pressure-Relief Devices
  • 10.2.4 Marking
  • 10.3.2 Specific Requirements
  • 10.3.2.1 Specific Requirements
  • 10.3.2.2 Minimum Distance
  • 11.2.3 Piping, Tubing, and Fittings
  • 11.2.5 Liquefied Hydrogen Vaporizers
  • 11.3.1.4 General

SAE J2600, Compressed Hydrogen Surface Vehicle Refueling Connection Devices (Society of Automotive Engineers, 2002)

Operation Approval Codes

The animation lists the following operation approval codes.

CGA G-5.4, Standard for Hydrogen Piping Systems at Consumer Locations (Compressed Gas Association, 2005)

  • 7.0 Maintenance and Repair

CGA G-5.5, Hydrogen Vent Systems (Compressed Gas Association, 2004)

  • 9 Maintenance

International Fire Code (International Code Council, 2009)

  • 105.6.8 Compressed Gases
  • 105.6.10 Cryogenic Fluids
  • 105.6.39 Repair Garages and Motor Fuel-Dispensing Facilities
  • 404 Fire Safety and Evacuation Plan
  • 404.3.2 Fire Safety Plans
  • 406 Employee Training and Response Procedures
  • 406.2 Frequency
  • 407 Hazard Communication
  • 901.6.2 Records
  • 906 Portable Fire Extinguishers
  • 907 Fire Alarm and Detection Systems
  • 907.2 Inspection, Testing, and Maintenance
  • 2204 Dispensing Operations
  • 2204.2 Attended Self-Service Motor Fuel-Dispensing Facilities
  • 2204.3 Unattended Self-Service Motor Fuel-Dispensing Facilities
  • 2204.3.5 Emergency Procedures
  • 2205.1 Tank Filling Operation for Class I, II, or IIIA Liquids
  • 2206.2.1.1 Inventory Control for Underground Tanks
  • 2209.3.2.3.2 Smoking
  • 2209.3.2.3.3 Ignition Source Control
  • 2209.3.2.6.2 Fire-Extinguishing Systems
  • 2209.3.2.6.3 Signage
  • 2209.4 Dispensing into Motor Vehicles at Self-Service Hydrogen Motor Fuel-Dispensing Facilities
  • 2209.5.1 Protection from Vehicles
  • 2209.5.2 Emergency Shutoff Valves
  • 2209.5.2.1 Identification
  • 2209.5.3 Emergency Shutdown Controls
  • 2209.5.4 Venting of Hydrogen Systems
  • 3204.5.2 Corrosion Protection
  • 3205.4 Filling and Dispensing
  • 3503.1.4 Ignition Source Control

NFPA 30A, Code for Motor Fuel Dispensing Facilities and Repair Garages (National Fire Protection Association, 2003)

  • 6.2 General Requirements
  • 6.3 Requirements for Dispensing Devices
  • 6.3.7 Requirements for Dispensing Devices
  • 7.3.5 Fixed Fire Protection
  • 9.2.2 Tank Filling and Bulk Delivery
  • 9.4 Operating Requirements for Attended Self-Service Motor Fuel Dispensing Facilities
  • 9.5 Operating Requirements for Unattended Self-Service Motor Fuel Dispensing Facilities

NFPA 52, Vehicular Gaseous Fuel Systems Code (National Fire Protection Association, 2010)

  • 9.2.3 Equipment Security and Vehicle Protection
  • 9.2.15 General System Requirements
  • 9.2.16 General System Requirements
  • 9.3.3.12 Warning Signs
  • 9.10.5 Installation of Emergency Shutdown Equipment
  • 9.13 System Operation
  • 9.14 Fire Protection
  • 9.15 Maintenance System
  • 14.2.1.6 General
  • 14.4.1 Liquid Hydrogen Vehicle Dispensing Systems
  • 14.4.2 Liquid Hydrogen Vehicle Dispensing Systems
  • 14.4.3 Liquid Hydrogen Vehicle Dispensing Systems
  • 14.4.5 Liquid Hydrogen Vehicle Dispensing Systems
  • 14.4.11 Liquid Hydrogen Vehicle Dispensing Systems

NFPA 55, Compressed Gases and Cryogenic Fluids Code (National Fire Protection Association, 2010)

  • 4.1 Permits
  • 4.2 Emergency Plan
  • 4.6 Personnel Training
  • 4.7 Fire Department Liaison
  • 4.8 Ignition Source Controls
  • 4.9 Signs
  • 6.12 Hazard Identification Signs
  • 7.1.6 Separation from Hazardous Conditions
  • 7.6.3 Ignition Source Control
  • 10.2.4 Marking
  • 10.3 Location of Gaseous Hydrogen Systems
  • 11.3.1.4 General