FM Global

Property Loss Prevention Data Sheets 7-39

October 2015
Page 1 of 23

LIFT TRUCKS

Table of Contents
Page

1.0 SCOPE ..................................................................................................................................................... 3

1.1 Changes ............................................................................................................................................ 3
2.0 LOSS PREVENTION RECOMMENDATIONS ......................................................................................... 3
2.1 Introduction ........................................................................................................................................ 3
2.2 Construction and Location ............................................................................................................... 3
2.2.1 All Lift Trucks ........................................................................................................................... 3
2.2.2 Battery-Powered Trucks .......................................................................................................... 3
2.2.3 Gasoline- and Diesel-Powered Trucks .................................................................................... 4
2.2.4 Gas-Powered Trucks ............................................................................................................... 4
2.3 Occupancy ........................................................................................................................................ 4
2.3.1 All Lift Trucks .......................................................................................................................... 4
2.3.2 Gasoline-Powered and Diesel-Powered Lift Trucks ................................................................ 6
2.3.3 Gas-Powered Lift Trucks ......................................................................................................... 6
2.3.4 Duel Fuel-Powered Lift Trucks ................................................................................................ 6
2.4 Protection ........................................................................................................................................... 6
2.5 Equipment and Process ................................................................................................................... 7
2.5.1 Gas-Powered Lift Trucks ........................................................................................................ 7
2.6 Operations and Maintenance ........................................................................................................... 7
2.6.1 All Lift Trucks ........................................................................................................................... 7
2.6.2 Gas-Powered Lift Trucks ......................................................................................................... 7
2.7 Training .............................................................................................................................................. 8
2.8 Electrical ............................................................................................................................................ 8
2.9 Safeguards for Indoor Hydrogen Fuel Dispensing ........................................................................... 8
2.9.1 General .................................................................................................................................... 8
2.9.2 Indoor Hydrogen Fueling Location and Construction ............................................................ 8
2.9.3 Hydrogen Fueling Occupancy ................................................................................................ 9
2.9.4 Protection for Hydrogen Fuel Areas ........................................................................................ 9
2.9.5 Hydrogen Fuel Dispensing Process and Controls .................................................................. 9
2.9.6 Operation and Maintenance of Hydrogen Dispensers .......................................................... 11
2.9.7 Training for Hydrogen Fueling Areas ..................................................................................... 11
2.9.8 Human Factors for Hydrogen Fueling ................................................................................... 12
2.9.9 Hydrogen Fueling Contingency Planning .............................................................................. 13
2.9.10 Ignition Source Control in the Refueling Area ................................................................... 13
3.0 SUPPORT FOR RECOMMENDATIONS ............................................................................................... 13
3.1 General ............................................................................................................................................ 13
3.1.1 Operation and Maintenance .................................................................................................. 13
3.2 Battery-Powered Trucks .................................................................................................................. 14
3.2.1 Ventilations Rates for Battery-Charging Rooms ................................................................... 14
3.2.2 FM Approved Types .............................................................................................................. 15
3.3 Gasoline-Powered Trucks ............................................................................................................... 16
3.3.1 FM Approved Types .............................................................................................................. 16
3.4 Diesel-Powered Trucks .................................................................................................................... 16
3.4.1 FM Approved Types .............................................................................................................. 16
3.5 LPG-Powered Trucks ...................................................................................................................... 16
3.5.1 FM Approved Types .............................................................................................................. 16
3.6 Dual Fuel-Powered Lift Trucks ........................................................................................................ 17
3.7 CNG-Powered Lift Trucks ................................................................................................................ 18

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Page 2 FM Global Property Loss Prevention Data Sheets

3.8 Hydrogen-Powered Lift Trucks (HPLTs) .......................................................................................... 18

3.8.1 Indoor Hydrogen Dispensing Hazards .................................................................................. 18
3.8.2 Release Prevention and Mitigation Safeguards .................................................................. 19
3.8.3 Release-limiting safeguards .................................................................................................. 19
3.8.4 Damage-limiting Building Volume (DLBV) ............................................................................. 21
3.8.5 Emergency Exhaust Ventilation ............................................................................................ 21
3.9 Loss History ..................................................................................................................................... 21
4.0 REFERENCES ...................................................................................................................................... 22
4.1 FM Global ........................................................................................................................................ 22
4.2 Other ................................................................................................................................................ 22
APPENDIX A GLOSSARY OF TERMS ....................................................................................................... 23
APPENDIX B DOCUMENT REVISION HISTORY ...................................................................................... 23

List of Figures
Fig. 1. Arrangement of components of LPG fuel system for industrial trucks ............................................ 17
Fig. 2. Simplified schematic showing hydrogen dispensing system RFO and ESD ................................... 19
Fig. 3. CFD simulation of indoor hydrogen releases ................................................................................... 22

List of Tables
Table 1. Recommended Types of Trucks for Various Occupancies ............................................................... 5
Table 2. RFO Flow Rate and Minimum Room Volume .................................................................................. 8
Table 3. Hazardous Electrical Areas for Hydrogen Fuel Dispensing Installations ...................................... 13

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Lift Trucks 7-39
FM Global Property Loss Prevention Data Sheets Page 3

1.0 SCOPE
This data sheet provides property loss prevention recommendations for the selection, operation, and
maintenance of various types of industrial lift trucks. Hazards associated with indoor hydrogen fueling are
also addressed.

1.1 Changes
October 2015. A new section was added to address safeguards for indoor fueling of lift trucks powered by
hydrogen fuel cells (Section 2.9).

2.0 LOSS PREVENTION RECOMMENDATIONS

2.1 Introduction
Use FM Approved equipment, materials, and services whenever they are applicable and available. For a
list of products and services that are FM Approved, see the Approval Guide, an online resource of FM
Approvals.

2.2 Construction and Location

2.2.1 All Lift Trucks

2.2.1.1 Provide a designated location for parking trucks during idle periods and separate the location from
manufacturing and storage areas using one of the following:
A. A minimum space separation of 5 ft (1.5 m) between the garaged trucks and combustibles
B. A one-hour fire-rated barrier between the garaging area and combustibles
2.2.1.2 Provide a designated location for service and repair of trucks and separate the location from
manufacturing and storage areas using one of the following:
A. A minimum space separation of 35 ft (11 m) between the service and repair area and combustibles
B. A one-hour fire-rated barrier between the service and repair area and combustibles
2.2.1.3 Provide guard rails, bollards, or telltales around piping exposed to damage near passageways and
at exposed drain, gage, and hose connections on sprinkler risers. Warning of overhead piping may be
suspended by metal strips (to create noise).

2.2.2 Battery-Powered Trucks

2.2.2.1 Locate single-panel charging installations serving one or two trucks so that readily ignited material
is not located closer than 5 ft (1.5 m) from the truck or the charging equipment. Do not place electrical chargers
within storage racking.
2.2.2.2 Locate multiple-panel battery-charging installations serving more than two trucks in a separate area
along an exterior wall (a cut-off room is preferred). Include the following features:
A. Maintain a minimum space separation of 5 ft (1.5 m) between any combustibles and the battery
chargers, if they are not located in a cut off room, or locate the battery charges within a cut-off room with
fire-rated walls.
B. Provide automatic sprinklers designed to deliver a density of 0.2 gpm (8 mm/min) over the most remote
2500 ft2 (230 m2) with a hose stream demand of 250 gpm (950 L/min) for a duration of 60 minutes. Use
FM Approved sprinklers with a temperature rating of 160°F (70°C).
C. Provide natural ventilation at high points in the exterior walls or roof.
2.2.2.3 In occupancies where lint, combustible dust, and flyings may be present, locate battery-charging
equipment in a separate room with positive pressurization arranged so the buildup of these materials about
the charging equipment can be minimized.
2.2.2.4 Provide physical protection around the battery chargers to prevent mechanical damage from lift trucks.

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2.2.3 Gasoline- and Diesel-Powered Trucks

2.2.3.1 Refuel gasoline and diesel-powered trucks out of doors or in a well-ventilated, detached building.
Refer to Data Sheet 7-32, Ignitable Liquid Operations, for guidance on adequate space separation.

2.2.4 Gas-Powered Trucks

The recommendations in this section relate to LPG-, CNG-, and hydrogen-powered lift trucks.
2.2.4.1 Provide an outdoor shelter or a detached building of lightweight noncombustible construction for
storage of lift trucks when not in use. If gas-powered trucks are stored indoors, adhere to all of the following:
A. Locate the trucks in a designated area within the building. If the building’s volume is less than that
stated below, provide a designated cut-off room with damage-limiting construction in accordance with Data
Sheet 1-44, Damage-Limiting Construction:
1. 180,000 ft3 (5,100 m3) for LPG
2. 110,000 ft3 (3,100 m3) for CNG
3. 87,500 ft3 (2,480 m3) for Hydrogen
B. Store the trucks at least 50 ft (15 m) from an MFL wall or sprinkler risers.
C. Provide automatic sprinkler protection in accordance with:
1. Data Sheet 7-50, Compressed Gases in Cylinders, for LPG- and CNG- powered trucks.
2. Data Sheet 7-91, Hydrogen, Section 2.4 for hydrogen-powered trucks.
D. Close the valve supplying fuel from the cylinder to the engine while parked in the designated storage
area.
2.2.4.2 LPG- and CNG-powered trucks having detachable fuel cylinders may be stored within the building
when not in use without the building volume limitations and safeguards recommended in Section 2.2.4.1 if the
fuel cylinders are removed prior to storage. When removing the tanks, follow the refueling procedure in
Section 2.2.4.5 for replacing LPG and CNG cylinders.
2.2.4.3 Store spare LPG and CNG cylinders outdoors in accordance with Data Sheet 7-50, Compressed
Gas in Cylinders.
2.2.4.4 Refuel trucks having permanently mounted LPG or CNG fuel cylinders, and refill detachable cylinders,
outdoors at least 50 ft (15 m) away from important buildings.
2.2.4.5 Detachable LPG and CNG fuel cylinders may be exchanged indoors at least 20 ft (6.0 m) away from
open flames or other ignition sources if, prior to disconnecting the empty tank, the fuel supply is shut off
at the tank and the engine is operated until all fuel in the system is consumed.
2.2.4.6 Locate LPG and CNG storage tanks up to 2,000 gal (7.6 m3) water capacity used for refueling trucks
having fixed fuel cylinders, and for refilling detachable cylinders, at least 50 ft (15 m) from important buildings.
Locate larger tanks in accordance with Data Sheet 7-55, Liquefied Petroleum Gas (LPG) in Stationary
Installations.

2.3 Occupancy

2.3.1 All Lift Trucks

2.3.1.1 Use battery-powered industrial trucks wherever possible to help limit the introduction of fuel into the
building.
2.3.1.2 Keep tops of storage piles as far as practical below sprinklers but not less than 3 ft (0.9 m) to reduce
the possibility of breakage of sprinklers and other overhead piping. This clearance also provides for water
distribution from sprinklers over the piles.
2.3.1.3 Use an appropriately rated lift truck to transport closed containers of ignitable liquid. Refer to Table
1 for guidance on determining the suitability of a lift truck for hazardous (classified) environments.

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FM Global Property Loss Prevention Data Sheets Page 5

Table 1. Recommended Types of Trucks for Various Occupancies

Types of Trucksb,c
Location Typical Occupancies FM Approved and Listed
Indoor or outdoor locations containing • Grocery warehouse Electrical: Type E
materials of ordinary fire hazard • Cloth storage Gasoline: Type G
• Paper manufacturing and working Diesel: Type D
• Textile processes except opening, LPG: Type LP
blending bale storage, and other CNG: Type CN
Class III locations Dual-fuel: Type G/LP or G/CN
• Bakery Hydrogen: Type H2
• Leather tanning
• Foundries and forge shops
• Sheet-metal working
• Machine-tool occupancies
Class I, Division 1a locations in which There are few areas in this division in Electric: Type EX
explosive concentrations of flammable which trucks would be used
gas or vapor may exist under normal Not recommended:
operating conditions, or where Gasoline, diesel, LPG, CNG, H2, and
accidental release of hazardous dual-fuel.
concentrations of such materials may
occur simultaneously with failure of
electrical equipment
Class I, Division 2a,e Locations in • Paint mixing, spraying, or dipping Electric: Type EE or EX
which ignitable liquid or flammable • Storage of flammable gases in Diesel: Type DY
gas is handled in closed systems or cylinders
containers from which they can • Storage of ignitable liquids in drums Not recommended:
escape only by accident, or locations or cans Gasoline, Diesel Types D & DS,
in which hazardous concentrations • Solvent recovery LP-Gas, CN-Gas, H2, and dual-fuel.
are normally prevented by positive • Chemical processes using ignitable
mechanical ventilation liquids
• Paper and cloth coating using
ignitable solvents in closed
equipment
Class II, Division 1a,f Locations in • Grain processing Electrical: Type EX
which explosive mixtures of • Starch processing
combustible dust may be present in • Starch molding (candy Not recommended:
the air under normal operating manufacturing) Gasoline, diesel types D, DS & DY,
conditions, or where mechanical • Wood/flour processing electrical E, ES & EE, LP-Gas, and
failure of equipment might cause such dual-fuel.
mixtures to be produced
simultaneously with arcing or sparking
of electrical equipment, or in which
electrically conductive dust may be
present
Class II, Division 2a Locations in • Storage and handling of grain, Electrical: Type EE or EX preferred
which explosive mixtures of starch or wood flour in bags or other Type ES
combustible dust are not normally closed containers Gasoline: Type GSd
present or likely to be thrown into • Grinding of plastic molding Diesel: Type DSd or DY
suspension through the normal compounds in tight systems LP-Gas: Type LPSd
operation of equipment, but where • Feed mills with tightly enclosed Dual-fuel: Type GS/LPSd and
deposits of such dust may interfere equipment GS/CNSd
with the dissipation of heat from
electrical equipment, or where such
deposits may be ignited by arcing or
sparks from electrical equipment
Class III, Division 1a Locations in • Opening, blending, or carding of Electrical: Type EE preferred, Type
which easily ignitable fibers or cotton or cotton mixtures ESa
materials producing combustible • Cotton gins Diesel: Type DY
brands are handled, manufactured, or • Sawing, shaping, or sanding areas
used in cordage plants Not recommended:
Gasoline, Diesel Types D & DS, LPG,
CNG, H2, or dual-fuel.

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7-39 Lift Trucks
Page 6 FM Global Property Loss Prevention Data Sheets

Types of Trucksb,c
Location Typical Occupancies FM Approved and Listed
Class III, Division 2a Locations in • Storage of textile and cordage fibers Electrical: Type ES
which easily ignitable fibers are stored • Storage of excelsior, kapok, or Gasoline: Type GSd
or handled (except in process of Spanish moss Diesel: Type DSd
manufacture) LP-Gas: Type LPSd
Dual-fuel: Type GS/LPSd and
GS/CNSd
a. Hazardous location as classified in the National Electrical Code (NFPA 70), and Sec. 32 of the Canadian Electrical Code. See Data Sheet
5-1, Electrical Equipment in Hazardous (Classified) Locations.
b. Type G (gasoline), Type D (diesel), Type LP (LP-Gas), and Type G/LP (gasoline and LP-Gas) trucks are considered to have comparable
fire hazards.
c. Type GS (gasoline), Type DS (diesel), Type LPS (LP-Gas), and Type GS/LPS (gasoline and LP-Gas) trucks are considered to have
comparable fire hazards.
d. Acceptable if kept clean and well maintained.
e. For Group D environments. Also valid for Group C environments if FM Approved for that environment.
f. For Group F and G environments.

2.3.1.4 Ensure a permanent label is present on all lift trucks that are rated for hazardous (classified) locations
to indicate that special safeguards have been provided.

2.3.2 Gasoline-Powered and Diesel-Powered Lift Trucks

2.3.2.1 Shut off the truck engine before gasoline of diesel refueling is started. Ensure the engine remains
off during refueling.
2.3.2.2 Exercise care to avoid spilling gasoline or diesel or overfilling the tank. Ensure spilled fuel has
dissipated or been flushed away before starting the engine.
2.3.2.3 Provide bonding and grounding between the hose nozzle or can spout and the tank to minimize
accumulation of static electricity.

2.3.3 Gas-Powered Lift Trucks

2.3.3.1 Use steel cylinders for LPG-powered lift trucks.
2.3.3.2 Do not expose gas-powered (LPG, CNG or hydrogen) trucks to high temperatures near ovens,
furnaces, or other sources of high temperature, except for extremely short intervals. Never leave the lift truck
unattended near ovens and furnaces.

2.3.4 Duel Fuel-Powered Lift Trucks

The following recommendations cover lift trucks powered by two fuels; either gasoline and LPG or gasoline
and CNG.
2.3.4.1 Follow the recommendations for both types of fuels used to power the lift truck.
2.3.4.2 Follow manufacturer’s recommended operating procedures for fuel supplies.

2.4 Protection
2.4.1 Provide fire extinguishers suitable for a fire involving the fuel used in the lift truck as follows:
A. Equip each gasoline, liquid petroleum gas (LPG), diesel, gasoline/LPG, battery-powered, compressed
natural gas (CNG), and hydrogen-powered industrial truck with a 5 lb (2.3 kg) dry chemical extinguisher
rated for ignitable liquids and gases.
B. Provide a 10 lb (4.5 kg) dry-chemical extinguisher at each gasoline or diesel refueling location rated
for ignitable liquids and gases.

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FM Global Property Loss Prevention Data Sheets Page 7

2.5 Equipment and Process

2.5.1 Gas-Powered Lift Trucks

2.5.1.1 Avoid exposing CNG and hydrogen cylinders to corrosive environments. Prolonged exposure can
cause weakening of the tank’s composite structure due to stress corrosion cracking, resulting in violent failure.
2.5.1.2 Provide interlocks on CNG tank refill dispensers to prevent CNG tanks being filled at pressures higher
than the working pressure of the fuel cylinder. Check dispenser pressure controls and relief valves monthly
for proper operation.

2.6 Operations and Maintenance

2.6.1 All Lift Trucks

2.6.1.1 Establish a system of regularly scheduled preventive maintenance. At a minimum, include the
following:
A. Periodic checks of fuel lines, carburetor, fuel tanks, electrical equipment, lubrication, and safety devices
B. Rubber, plastic, or composite hoses
C. Re-filling connections on fuel tanks
If any deficiencies are identified, have the truck removed from service and repaired.
2.6.1.2 Keep written records of the maintenance activities showing the type of service and any repairs that
are made.
2.6.1.3 Ensure all maintenance and repairs are carried out by qualified personnel.
2.6.1.4 Ensure replacement parts comply with manufacturer’s specifications and maintain the certification
of the correct hazardous (classified) environment (e.g., ensure replacement batteries for type EX electric lift
trucks are listed for flammable or explosive environments).
2.6.1.5 Check when reinstalling batteries after charging that they are an equivalent or higher rating than the
battery type marked on the rated lift truck.
2.6.1.6 Keep trucks free from accumulations of oil, grease, and lint. Clean with steam or alkaline solutions.
2.6.1.7 Keep all enclosures and protective covers around the engine and exhaust system in place at all times
when trucks are operating. This is particularly important with battery-powered trucks used in hazardous
(classified) locations because safe operation is dependent on these enclosures.

2.6.2 Gas-Powered Lift Trucks

2.6.2.1 Provide a documented preventive maintenance program that includes frequent recorded inspections
of the gas fuel supply and delivery system to avoid creating hazardous conditions as a result of the escape
of the LPG, CNG, or hydrogen.
2.6.2.2 Visually inspect the cylinders for physical damage prior to use.
2.6.2.3 Do not fill permanently mounted fuel tanks beyond the maximum filling capacity according to the
following temperature at filling point: 80% of liquid capacity between 10°F and 40°F (-12°C and 4°C) or 85%
of liquid capacity between 40°F and 70°F (4°C and 21°C).
2.6.2.4 Fill compressed gas cylinders by weight in accordance with the listing agency’s standard (e.g., fill
U. S. Department of Transportation [DOT] cylinders in accordance with DOT regulations).
2.6.2.5 Have all flammable gas cylinders inspected and requalified when they reach the end of their design
life (the design life will be specified by the cylinder manufacturer). Ensure fuel tanks that do not pass
requalification are emptied and disposed of safely.

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2.7 Training
2.7.1 Restrict the use of industrial trucks to personnel trained in their operation. Establish the following rules,
at a minimum:
A. Operators will exercise particular care when moving high-raised loads.
B. Operators will exercise particular care when loading goods into racking with in-rack sprinklers present.
C. Operators will set brakes and shut off engine, or put the controls in neutral (battery-powered), before
leaving a truck unattended.
D. Operators will not handle leaking or open containers of ignitable liquid with industrial trucks.

2.8 Electrical
2.8.1 Install all battery charging equipment in accordance with the standards of the National Electrical Code
(NEC or local equivalent).

2.9 Safeguards for Indoor Hydrogen Fuel Dispensing

2.9.1 General
2.9.1.1 Locate lift truck fueling stations outdoors or in a detached building where feasible.
2.9.1.2 Locate and arrange bulk hydrogen storage, compression equipment, and supply piping outdoors in
accordance with Data Sheet 7-91, Hydrogen.
2.9.1.3 Design and install hydrogen-dispensing systems in accordance with this data sheet as well as
applicable code requirements and industry standards (see Section 4.0).
2.9.1.4 Where industrial lift trucks are fueled with hydrogen inside main buildings, follow the recommendations
in Sections 2.9.2 through 2.9.10.

2.9.2 Indoor Hydrogen Fueling Location and Construction

2.9.2.1 Locate the hydrogen dispenser inside a room or building of minimum volume as determined in Table
2 based on the maximum hydrogen flow rate for a severed supply line (see Section 2.9.5.4).

Table 2. RFO Flow Rate and Minimum Room Volume

Maximum hydrogen flow rate* Minimum room volume
Lb/min (kg/min) ft3 (m3)
2.2/min (1/min) 710,000 (20000)
4.4 (2) 1,100,000 (32000)
6.6 (3) 1,800,000 (51000)
8.8 (4) 2,400,000 (68000)
*
Based on severed supply line - see Section 2.9.5.4

Further discussion on the flow rates and volume thresholds shown in Table 2 is provided in Section 3.8.4.
2.9.2.2 If the room or building volume is less than that indicated in Table 2, provide a dedicated mechanical
emergency exhaust system over the dispensing area in accordance with Section 2.9.5.6.
2.9.2.3 Locate the dispenser near an exterior wall with direct access from outdoors and a fire resistance
rating of at least 1 hour extending at least 20 ft (6 m) horizontally and vertically from the dispenser.
2.9.2.4 Provide space separation from the dispensing area to the following exposures:
A. At least 25 ft (7.5 m) from combustible storage, combustible in-process materials and construction,
building corners, and hazardous processes.
B. At least 50 ft (15 m) from sprinkler risers and maximum foreseeable loss (MFL) walls. (See Data Sheet
1-22, Maximum Foreseeable Loss, for a description of MFL walls).

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FM Global Property Loss Prevention Data Sheets Page 9

2.9.2.5 Locate the piping entry above ground using the shortest possible indoor route to the dispenser,
minimizing the length of piping inside the building.
2.9.2.6 Protect hydrogen piping and dispensers against potential accidental impact during maintenance
activities or by lift trucks. Means of protection include combinations of administrative controls, signage,
barriers (bollards and guard rails), and piping guards, as well as locating the hydrogen piping and dispenser
in areas that have less traffic and are less exposed to impact during normal facility operations and building
maintenance work.
2.9.2.7 Where dispensing systems are located in FM Global 50-year through 500-year earthquake zones
(as defined in Data Sheet 1-2, Earthquakes), provide the following seismic-related safeguards:
A. Perform a seismic-loading analysis based on ASCE 7 or other recognized code to ensure supports
for piping, dispensers, and outdoor equipment have been designed to resist the anticipated seismic loads.
B. Provide seismic shutoff on the hydrogen dispenser emergency shutdown system (ESD) in accordance
with Section 2.9.5.5 of this data sheet and recommendations in DS 1-11, Fire Following Earthquake.
C. Where hydrogen supply piping penetrates walls and roofs, provide clearance in accordance with DS
1-11.

2.9.3 Hydrogen Fueling Occupancy

2.9.3.1 Ensure good housekeeping is strictly maintained in the fueling area. Good housekeeping includes
unobstructed access, no extraneous materials, no ignitable liquids, and no other combustibles within 25 ft (7.5
m).
2.9.3.2 Conduct regular recorded housekeeping inspections and provide a management reporting channel
to ensure any identified deficiencies are corrected promptly.

2.9.4 Protection for Hydrogen Fuel Areas

2.9.4.1 Provide ceiling sprinkler protection over hydrogen dispensing areas and ensure it is adequate for
the surrounding occupancy per the appropriate FM Global data sheet, but not less than HC-2. (For HC-2
design criteria, see Data Sheet 3-26, Fire Protection Water Demand for Nonstorage Sprinklered Properties).

2.9.5 Hydrogen Fuel Dispensing Process and Controls

2.9.5.1 Utilize dispensing hoses and break-away devices listed for hydrogen dispensing.
2.9.5.2 Utilize SAE J2600 compliant fueling connection devices (nozzles and receptacles).
2.9.5.3 Provide the following features in the design and installation of the dispenser:
A. Prior to final design of the dispenser, conduct a team-based, documented, site-specific hazards analysis
using known methods such as “What-if,” “Check-list,” or HAZOPS. Involve key facility personnel in the
review and evaluation of dispenser safeguards.
B. Ensure all action items identified by the hazards analysis are completed prior to startup of the dispensing
system.
C. Maintain a copy of the hazards analysis documentation onsite for review.
D. Design the fuel protocol in accordance with SAE J2601-3 for “fill to target” or “fill to service pressure”
methods.
E. Use welded supply piping in accordance with ASME B31.12, “Hydrogen Piping and Pipelines”.
F. Provide hydrogen venting systems in accordance with CGA G-5.5, “Hydrogen Vent Systems”.
2.9.5.4 Install a restrictive flow orifice (RFO) or other passive flow restricting means on the hydrogen supply
piping upstream of the piping entry into the building as follows:
A. Size the RFO or other flow restriction to meet fueling needs, but also to meet the flow rates in Table
2 and local code requirements.

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B. Obtain piping drawings and flow calculations from the dispensing station installer demonstrating that
the designated maximum flow rate will not be exceeded at the maximum upstream supply pressure and
with flow through 100% of the severed pipe cross sectional area at the entry to the building.
C. Maintain a copy of the piping drawings and flow calculations onsite for management-of-change
purposes.
2.9.5.5 Provide an emergency shutdown system (ESD) on the hydrogen dispenser in accordance with the
following:
A. Install a dedicated safety shut-off valve (SSOV) on the hydrogen supply line outside the building and
in a readily accessible location. Utilize an FM Approved valve if available and suitable for the application.
B. Install local and remote e-stops in locations that will be accessible to manually activate the SSOV in
event of an emergency during dispensing.
C. Provide sensors to automatically detect hazardous conditions including the following conditions:
1. Hydrogen gas more than 10% of LEL in dispenser cabinet
2. Hydrogen gas more than 10% of LEL at ceiling level above the dispensing area
3. Hydrogen flame in the dispensing area (optical detection)
4. Sprinkler system water flow in the dispensing area
5. Dispensing system leak
6. Lift truck “pull-away” (with hose still connected)
7. Piping breaks or other large leaks
8. Critical deviations or upsets during refueling, as determined by hazards analysis of the dispensing
system
9. Internal (watchdog) timer timed out
10. Seismic activity in earthquake prone areas (see Section 2.9.2.7)
D. Utilize FM Approved hydrogen gas and flame detectors.
E. Arrange the sensors recommended in Part C so activation of any one of them will trip the SSOV by
a hard-wired circuit and/or a dedicated programmable electronic system (PES) that is independent of the
process controller.
F. Design the ESD as a safety instrumented system (SIS) with a minimum Safety Integrity Level 1 (SIL
1).
G. Submit ESD documentation to FM Approvals for independent review and certification of the SIL rating
prior to installation.
H. Conduct proof testing in accordance with a documented procedure to ensure the fueling protocol is
satisfied and all dispenser ESD safety functions are performed as designed prior to startup. Review records
of all testing and keep on file for future reference.
The rationale for recommending a certified SIL 1 ESD is discussed in Section 3.8.3.1.
2.9.5.6 Where a dedicated mechanical emergency exhaust system is provided per Section 2.9.2.2, design
as follows:
A. Interlock to require ventilation being in operation prior to startup and continuously during hydrogen
dispensing operations.
B. Provide accessible local and remote manual activation devices, as well as automatic activation by the
use of hydrogen gas detectors in the dispensing area.
C. Locate intakes at the roof level above the dispenser and arrange to prevent potential accumulation
of hydrogen in any unavoidable “pockets” formed by roof beams or draft curtains.
D. Provide 100% exhaust to outdoors.

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E. Provide sufficient exhaust (based on documented airflow modeling) to capture and remove the released
hydrogen and also limit the average hydrogen concentration in the exhaust air to no more than the LEL
(4%) at the maximum flow hydrogen rate allowed by the RFO (as calculated per Section 2.9.5.4).
2.9.5.7 Provide controls to prevent the lift truck from being inadvertently driven away from the dispenser
with the fueling nozzle still connected. Controls include administrative measures and/or active devices to
prevent starting the lift truck if the transfer hose is still connected.

2.9.6 Operation and Maintenance of Hydrogen Dispensers

2.9.6.1 Establish administrative controls and designate responsible supervisory personnel to ensure
employees and contractors adhere to all operating and maintenance procedures.
2.9.6.2 Use qualified employees and/or contractors to supervise and perform all operation and maintenance
duties for hydrogen storage and dispensing.
2.9.6.3 Establish and adhere to documented operating procedures, including the following:
A. Normal startup and shutdown
B. Supervision during dispensing
C. Emergency shutdown system
D. Roster of personnel trained and authorized on each shift to conduct dispensing and to manually activate
the ESD system in emergency situations.
2.9.6.4 Adhere to documented preventive maintenance procedures in accordance with facility experience
and equipment manufacturers’ guidelines.
2.9.6.5 Conduct regular recorded maintenance and inspection of the refueling system according to
manufacturers’ directions and facility experience.
2.9.6.6 Establish procedures to identify and promptly report equipment failures, leakage, corrosion, operator
error, near-miss events, and other abnormal conditions to the appropriate supervisor.
2.9.6.7 Calibrate gas detectors on a quarterly basis, or more frequently if warranted based on plant experience
or manufacturers’ recommendations.
2.9.6.8 Test the performance of all manual and automatic emergency shutoff devices annually, or more
frequently if recommended by the device manufacturer or if warranted by facility experience.
2.9.6.9 Test excess-flow valves (if provided) and excess flow switches (if provided) as recommended by the
equipment manufacturer.
2.9.6.10 Replace or recondition all safety devices based on manufacturers’ recommendations, and when
necessary due to damage or other poor condition.

2.9.7 Training for Hydrogen Fueling Areas

2.9.7.1 Create a training program for employees who have access to the hydrogen refueling area, including
operators, emergency responders, and maintenance and security personnel. Include at least the following
subjects in the training program:
A. The hazards created by hydrogen storage and dispensing
B. Proper operation and shutdown of equipment under normal and emergency procedures
C. Location of all local and remote manual shutoff stations
D. Operator authorization to manually activate ESD when judged appropriate in emergency situations
E. Near-miss reporting procedures
2.9.7.2 Ensure all contractors working in or around the refueling area have adequate training in hydrogen
hazards related to their assigned duties.
2.9.7.3 Train contractors to follow facility procedures for notification and response to hydrogen emergencies.

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2.9.8 Human Factors for Hydrogen Fueling

2.9.8.1 Property Conservation

2.9.8.1.1 Address hydrogen hazards and prevention of accidental hydrogen releases as part of a documented
property conservation program in accordance with DS 9-7, Property Conservation, including the following:
A. Prepare a written property conservation policy.
B. Establish authority and responsibilities.
C. Organize responders to handle emergencies.
D. Educate and train.
E. Audit and update.

2.9.8.2 Emergency Response and Pre-Fire Planning for Hydrogen Fueling

2.9.8.2.1 Establish an emergency response plan for accidental hydrogen releases that includes at least the
following elements:
A. Overall plan in accordance with DS 10-2, Emergency Response
B. Pre-incident plan in accordance with DS 10-1, Pre-Incident Planning
C. Site plan showing the location of all hydrogen dispensers and emergency isolation stations
D. Documented authorization for designated personnel on all shifts to activate the ESD when warranted
based on individual judgment
E. Availability of fire protection for cooling exposed hydrogen-powered lift trucks in the refueling area
F. Responder awareness that hydrogen fires are invisible and must not be extinguished until the release
source has been shut down
2.9.8.2.2 Familiarize the facility’s emergency response team members and the local fire service with the
location of dispenser installations as well as the emergency response plan.
2.9.8.2.3 Conduct annual emergency response drills to reinforce the employee and contractor training
program and to familiarize the fire service with the site layout and dispensing area arrangements.

2.9.8.3 Supervision of Hydrogen Fueling Loss Prevention Programs

2.9.8.3.1 Keep loss prevention documentation current and readily accessible at the facility for review and
use in management of change, loss prevention audits, hazards assessments, and emergency response.
2.9.8.3.2 Ensure hydrogen-related loss prevention programs are supervised by employees trained in
hydrogen handling and emergency response procedures.

2.9.8.4 Supervision of Hydrogen Supply and Equipment Contractors

2.9.8.4.1 Develop and implement a program to supervise contractors in accordance with the
recommendations in Data Sheet 10-4, Contractor Management, including the following:
A. Draft a formal policy statement on contractor supervision, along with procedures for selecting, inducting,
and supervising contractors.
B. Assign an employee to be accountable for ensuring the contractor policy and procedures are followed,
audited regularly, and updated as necessary.
C. Post the contractor policy and ensure the information is communicated to all employees and contractors
involved with the dispensing area.
D. Define and document the work to be completed by the contractor.
E. Specify the codes and standards and other requirements the contractor must comply with in performing
the work.

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F. Identify any equipment and maintenance activities that remain the responsibility of the facility, and how
facility and contractor personnel will interact.
G. Review completed work and records to ensure contract requirements are met.

2.9.9 Hydrogen Fueling Contingency Planning

2.9.9.1 Establish a documented contingency plan to help limit potential production downtime due to
mechanical damage, fire, explosion, or other disruption of the hydrogen supply and dispensing system.
2.9.9.2 Conduct periodic reviews and updates to ensure the contingency plan remains current.

2.9.10 Ignition Source Control in the Refueling Area

2.9.10.1 Do not allow hot work on or around hydrogen dispenser installations.
2.9.10.2 Relocate unavoidable hot work to a nonhazardous location or, when relocation is not possible, use
a permit system in accordance with DS 10-3, Hot Work Management, to strictly control all hot work
operations.
2.9.10.3 Issue permits only after conducting a thorough review of all proposed work. Document the procedure
and evaluate the specific hazards in the area as well as all precautions needed to prevent fire or explosion.
If all of the requirements cannot be met, do not issue the permit and do not allow the work to be performed.
2.9.10.4 Design electrical installations for hazardous electrical areas in accordance with the recommendations
in Data Sheet 5-1, Electrical Equipment in Hazardous (Classified) Locations, and applicable electrical codes.

2.9.10.5 Provide hazardous area rated electrical equipment per Table 3.

Table 3. Hazardous Electrical Areas for Hydrogen Fuel Dispensing Installations

Area1 Class 1 Div 1 or Zone 1 Class 1 Div 2 or Zone 2
Dispensing nozzle during refueling 0 to 5 ft (1.5 m) 5 ft (1.5 m) to 15 ft (4.6 m)
Pressure-relief device discharge path 0 to 5 ft (1.5 m) 5 ft (1.5 m) to 15 ft (4.6 m)
(not in direct path)
1
Distance in all directions from the source of release.

3.0 SUPPORT FOR RECOMMENDATIONS

3.1 General
Industrial trucks are used at facilities, both indoors and outdoors, for moving and lifting materials. They are
essential to the operation of most facilities because of their efficiency in material handling. Their use,
however, introduces hazards of fire, explosion, mechanical damage, and water damage.
Lift trucks have made it possible to pile storage to greater heights, increasing the difficulties of firefighting
and, unless proper clearances are maintained, decreasing the effectiveness of sprinklers. Also, collisions with
sprinkler piping can impair protection and release quantities of water on equipment or goods.
Some of the largest losses on record have occurred when lift trucks handling ignitable liquid have dropped
their loads, breaking or spilling the liquid from the containers, which is then ignited by hot surfaces or sparks
from the truck.
Industrial trucks are available in various designs to suit the type of load to be handled. They are powered
by storage batteries and by gasoline, diesel, LPG, CNG, hydrogen, or combination gasoline and LPG or
gasoline and CNG (dual-fuel) engines.

3.1.1 Operation and Maintenance

Careless operation of industrial trucks can lead to severe damage in many forms, including physical damage
to building fixtures. Widespread damage may occur if water is released from a broken pipe or fitting on an
automatic sprinkler or industrial water system. Fire doors and other important fire protection equipment
intended to limit the size or spread of fire may be rendered inoperative by being struck by a truck. Mechanical
damage to process piping, equipment, drums, or tanks may release ignitable liquids or other hazardous
material, causing fire.

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In the period 1989 through 2008, sprinkler pipe breakage accounted for nearly one-third of all losses reported
to FM Global involving lift trucks. Sprinkler leakage resulting from lift truck operation is most likely to occur
in storage areas where trucking activities are concentrated. Most accidents have been caused by careless
operation of high-lift trucks. Operators failed to consider sprinkler piping while raising stock, or failed to leave
adequate clearance between a load and overhead piping while moving with the mast raised. Gauge
connections at risers, hose connections, feeder mains, and even risers have been broken. In a few reported
cases, a section of roof collapsed when a column was knocked out from under it.
Operators of industrial-truck fleets have established courses of instruction for prospective truck operators
to lessen chances of accidents and decrease equipment wear. Accidents endanger equipment and buildings,
fire-protection equipment, truck operators, and other personnel. Industrial trucks make numerous stops and
starts and work much of the time under heavy load. This hard service causes excessive wear on trucks if
inexperienced or improperly trained operators are permitted to use them.
The severe service to which industrial trucks are subjected should be recognized in arranging truck-
maintenance schedules. Fire hazard is increased by the operation of dirty, poorly maintained trucks. Failure
of control equipment may result in damage to the building or sprinkler piping.

3.2 Battery-Powered Trucks

Insulation, battery boxes, and accumulated grease deposits on a battery-powered truck are combustible
material that could be ignited and involve the truck in a fire.
The principal source of ignition is short circuits in wiring. Fires have also resulted from current being left on,
ignitable liquid being unsafely carried, and collision.
Small quantities of hydrogen evolve from a battery on charge and can introduce a potential fire and explosion
hazard. An electrical disturbance may cause a fire in grease and dirt on the truck, insulation, or charging
equipment.

3.2.1 Ventilations Rates for Battery-Charging Rooms

During the recharging process, a lead battery releases hydrogen and oxygen through the electrolysis of
sulfuric acid. The beginning of gassing is determined by the battery voltage. The amount of gas created
depends on the current that isn’t absorbed by the battery, and can be used in the electrolysis process.
As the battery reaches its full state of charge, the acceptance of current becomes less, and more hydrogen
is liberated.
If ventilation is required it needs to maintain the concentration of hydrogen vapor at or below 25% of the
lower explosive limit (LEL). The LEL for hydrogen in air is 4%, so maintaining the hydrogen vapor
concentration in a room at or below 25% LEL equates to 1% hydrogen concentration.
The ventilation requirements are dependent on the rate of hydrogen being released. The equation below
can be used to determine the amount of hydrogen being liberated from the batteries.
English Units:

H = Ah x dF x Cn x α
Where:
H is the rate of release of hydrogen vapor (ft3/hour).
Ah is the total ampere hours of all the batteries.
dF is the finish rate (overcharge); if unknown, assume 5% (as a fraction, e.g., 0.05).
Cn is the total number of cells for all the batteries.
α is the average release rate of hydrogen generation (ft3/Ampere hour/cell). An of 0.016 can be assumed
based on commonly used batteries.

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Metric Units:

H = 0.03 Ah x dF x Cn x α
Where:
H is the rate of release of hydrogen vapor (m3/hour).
Ah is the total ampere hours of all the batteries.
dF is the finish rate (overcharge); if unknown, assume 5% (as a fraction, e.g., 0.05).
Cn is the total number of cells for all the batteries.
α is the average release rate of hydrogen generation (m3/Ampere hour/cell). An of 0.0045 can be assumed
based on commonly used batteries.
Once the rate of release of hydrogen vapor is known, the ventilation rate needed to maintain concentrations
at or below 25% LEL can be determined. The equation below can be used to determine the ventilation rate
required.
English Units:
26H
/
ACH = CH2 - H 0.0043Vspace
Where:
ACH is the number of air changes per hour.
H is the total hydrogen discharge within the room (gpm).
CH2 is the concentration of hydrogen within the room (%).
Vspace is the volume of the room (gal).

Metric Units:
100H
/
ACH = CH2 - H 0.0167Vspace
Where:
ACH is the number of air changes per hour.
H is the total hydrogen discharge within the room (L/min).
CH2 is the concentration of hydrogen within the room (%).
Vspace is the volume of the room (liters).

3.2.2 FM Approved Types

Battery-powered trucks are available in four types, specially designed and safeguarded for use in locations
ranging in hazard from ordinary to extra:
A. Type E trucks have the minimum necessary safeguards and are for use in ordinary-hazard areas.
B. Type ES trucks have additional safeguards to prevent emission of sparks from the electrical system
and to limit surface temperatures. They are recommended for areas where easily ignitable fibers are stored
or handled (except in the process of manufacturing).
C. Type EE trucks have their electric motor and all other electrical equipment completely enclosed and
are recommended for use in hazardous locations other than those that require Type EX.
D. Type EX trucks are of explosion proof (Class I, Group D), or dust-tight (Class II, Group G) construction
and are recommended for areas where there are likely to be explosive mixtures of flammable vapor or
combustible dust during normal operations.

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3.3 Gasoline-Powered Trucks

Most of the reported fires involving gasoline-powered industrial trucks were the result of gasoline spills during
refueling. Other fires resulted from breaks or leaks in gasoline connections. The released gasoline can be
ignited by the hot engine, by the ignition system when starting, by other electrical equipment, and by exhaust
or other sparks. Other fires result from defective insulation on wiring, greasy deposits, or leaking hydraulic
oil. Some are caused by exhaust sparks igniting combustibles in the vicinity, and some result from upsets and
collisions.
Potential fire sources that cannot be completely eliminated by safeguards include gasoline that may leak
from the fuel, starting, and ignition systems, and sparks from the exhaust system. Limitations on locations
in which gasoline-powered trucks may be used are recommended.

3.3.1 FM Approved Types

Two types of FM Approved gasoline-powered trucks are available: Type G and Type GS. Type G trucks have
the minimum necessary safeguards and are recommended for use in occupancies of light fire hazard. Type
GS trucks have additional safeguards in the electrical exhaust and fuel systems and are recommended for
occupancies where there are readily ignited combustible materials, as outlined in Table 1. When ordering,
specify the complete listed type designation to ensure the proper safeguards will be supplied.

3.4 Diesel-Powered Trucks

Diesel-powered trucks, except the specially safeguarded Type DY, are similar to gasoline-powered trucks.
However, the fuel hazard is less than that of gasoline-powered trucks because of the higher flash point of
diesel fuel. Loss experience with diesel-powered trucks has been limited. Less than 5% of the reported
industrial truck losses involved diesel-powered trucks.

3.4.1 FM Approved Types

Three types of FM Approved trucks are available: Types D, DS, and DY. The fire hazard of Types D and
DS are considered comparable to Types G and GS gasoline-powered trucks, respectively.
The Type DY diesel-powered truck is equipped with additional safeguards that make it less hazardous than
a Type DS truck. Surface and exhaust gas temperatures are limited to a maximum of 325°F (163°C), there
is no electrical system, and other safeguards are provided to minimize the fire hazard normally associated
with internal-combustion engines.

3.5 LPG-Powered Trucks

LPG-powered trucks not only present the same hazards as gasoline-powered trucks, but also those of a
combustible gas under high pressure.
The greatest potential danger is ignition of gas leaking from poorly maintained fuel connections being released
during operation of the relief valve. Operation of the relief valve is possible from overfilling, fire exposure
to the container, and high local temperatures near ovens, furnaces, or other high-temperature equipment.
About two-thirds of the fires and explosions involving LPG trucks result from breaks or leaks in the fuel
connections.
Special safeguards reduce the hazard of gas leakage during normal operation and refueling (see Figure
1). As with gasoline-powered trucks, the hazards of LPG-powered trucks cannot be eliminated completely
by safeguards. Therefore, limitations on locations in which they may be used is recommended.
A liquid-withdrawal system is illustrated. In a vapor-withdrawal system the vaporizer would be omitted but
the regulator would be retained, the hot water lines would be omitted, and the hydrostatic relief valve would
not be required.

3.5.1 FM Approved Types

Two types of FM Approved trucks are available: Type LP and Type LPS. The fire hazard of these trucks is
comparable to Types G and GS gasoline-powered trucks, respectively.

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Fig. 1. Arrangement of components of LPG fuel system for industrial trucks

3.6 Dual Fuel-Powered Lift Trucks

Dual fuel-powered trucks that are factory assembled have been FM Approved. These trucks are capable of
being powered by either gasoline or LPG. They are available as Type G/LP and Type GS/LPS. They have
the hazards and limitations of both gasoline and LPG-powered industrial trucks.

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3.7 CNG-Powered Lift Trucks

CNG-powered trucks are similar to LPG-powered trucks. Loss history for CNG-powered industrial trucks is
limited, which may be due to their restricted use in industry.
Recent losses in the automotive industry, where CNG-powered vehicles are becoming more common, are
similar to those of LPG, with one exception. The cylinders for CNG are made of a composite material that is
susceptible not only to mechanical damage but to breakdown if exposed to corrosive environments and can
weaken if constantly overfilled.
As with LPG-powered trucks, CNG-powered trucks are fitted with special safeguards to reduce the hazard
of gas leakage during normal operations and refueling. However, the hazard cannot be eliminated completely
by safeguards. Therefore, limitations on locations in which they may be used are recommended.

3.8 Hydrogen-Powered Lift Trucks (HPLTs)

The power source for HPLTs is typically a battery replacement module (BRM) that contains a fuel cell or a
hybrid fuel cell/battery system designed to replace conventional battery packs. Hydrogen gas is stored in an
onboard reservoir with a typical water capacity of up to 4.8 gal (18 L) at a very high pressure. As an example,
an H35-rated lift truck has a nominal working (service) pressure of 5100 psi (35 MPA; 350 bar). These high
pressures are necessary to fill the reservoir with sufficient hydrogen (approximately 4.4 lb [2 kg]) to operate
the lift truck for several hours before the next fueling.

3.8.1 Indoor Hydrogen Dispensing Hazards

Liquid and gaseous fuel dispensing for lift trucks has historically been conducted outdoors to help isolate
the fire and explosion hazards from end use areas such as storage and manufacturing operations. In contrast,
indoor fueling of HPLTs is typically preferred by end users for improved housekeeping and sanitation
purposes, as well as better operating efficiency.
Hydrogen has a very wide flammable range (4% to 75% by volume) and also requires very little energy to
ignite; a flammable hydrogen-air mixture could be formed under high-pressure release conditions following
impact by a heavy object, hose rupture, or as a result of human error. The cloud could subsequently ignite
from a weak discharge of static electricity, ordinary electrical equipment, or other ignition source. As discussed
below (Section 3.8.4), gas dispersion modeling indicates that such clouds are capable of causing
overpressure damage to the building and its contents. Ignition of an uncontrolled hydrogen release could
also result in an almost invisible jet flame capable of igniting nearby combustibles. Manual firefighting
becomes very difficult under these conditions.
Accidental releases of hydrogen gas can occur for a number of reasons, including the following:
• Degradation of the gas cylinder (erosion of the liner within the cylinder)
• Incompatible piping materials
• Improper sealing of the nozzle to the tank
• Delivery of gas while nozzle is not connected
• A leak in the pipe connecting the filling station with bulk tank (pipes tend to be the weakest point
in a hydrogen-dispensing system)
• A leak at the connections between filling station and pipes or bulk tank and pipes
• The rupture of pipes due to hydrogen embrittlement
Many safeguards are provided to help prevent accidental hydrogen releases during fueling. As a result,
property loss experience with dispensing to HPLTs has been favorable. However, lift truck fueling is an
inherently hazardous operation; it is critical to ensure hydrogen dispensing systems located indoors in
high-value end-use areas are managed (i.e., designed, installed, and operated) to prevent accidental releases
and, if releases do occur, to mitigate potential damage.

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3.8.2 Release Prevention and Mitigation Safeguards

The primary defense against fires and explosions involving hydrogen, or any other flammable gas, is to
prevent accidental releases from occurring in the first place. Hydrogen release prevention depends primarily
on the following:
• Robust equipment design (lift truck fuel tanks, nozzles, hoses, piping and dispensers)
• Regular inspection and maintenance of piping, dispensers and lift trucks
• Trained personnel who follow proper operating and maintenance procedures at all times
However, even where primary release prevention safeguards are fully implemented, fueling system failures
can occur and may result in large releases. For example, releases might be caused by accidental impacts,
equipment failure, breaks in supply piping and hoses, failure to follow maintenance or operating procedures,
or other human errors. To help mitigate the potential damage should such a release occur, the following
additional safeguards are recommended in this data sheet:
• Release-limiting safeguards (Section 3.8.3)
• Damage-limiting building volume (Section 3.8.4)
• Emergency exhaust ventilation (Section 3.8.5)

3.8.3 Release-limiting safeguards

By limiting both the flow rate and duration of the accidental release, the amount of hydrogen available in a
potential fire and/or explosion can be significantly reduced (along with the severity of the consequences)
compared to a large “uncontrolled” release event.
Two key “release-limiting” safeguards are recommended in this data sheet and are also required by codes:
(1) an emergency shutdown system (ESD,) and (2) a restrictive flow orifice (RFO). These are illustrated
schematically in Figure 2 and discussed below.

Fig. 2. Simplified schematic showing hydrogen dispensing system RFO and ESD

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3.8.3.1 Emergency Shutdown System (ESD)

The dispenser ESD system recommended in Section 2.9.5.5 is intended to provide the following basic safety
shutdown functions:
• Allow prompt manual shutdown of the hydrogen supply in case of emergency.
• Achieve automatic shutdown of the hydrogen supply outside the building prior to or promptly following
an accidental hydrogen release during dispensing.
The following are the key components of the ESD system:
A. A safety shut-off valve (SSOV) located outside the building and dedicated solely to the above safety
functions.
B. Hydrogen gas and hydrogen flame detectors in the dispensing area.
C. Sensors to detect critical process deviations during dispensing as determined by a hazards analysis.
For example, high pressure or temperature conditions may be critical; a pipe leak or hose break may
be detected by pressure sensors. ESD sensors are independent of the process control sensors.
D. A programmable electronic system (PES, also sometimes called a “safety PLC”) and/or “hard-wiring”
to activate the SSOV independently of the dispenser PLC.
As long as the ESD performs as intended, the hydrogen supply will be shut down outside the building, and
indoor hydrogen releases will be either prevented or limited to a very short duration. Failure of the ESD
system to perform in a large release situation could result in a much longer-duration release, a large hydrogen
cloud, and much greater damage if an explosion occurs. Therefore, reliable ESD performance is critical in
terms of damage mitigation.
This data sheet recommends that hydrogen dispenser ESDs located inside large manufacturing buildings
and warehouses be designed in accordance with established international standards for safety instrumented
systems (e.g., IEC EN 61508) for at least Safety Integrity Level 1 (SIL 1).
A SIL 1 SIS (or ESD), by definition, is expected to operate successfully between nine out of ten and ninety-nine
out of one hundred “demands.” SIL 1 is the lowest ranked performance level and the least expensive to install
in terms of SIL-compliant hardware and software. (SIL 4 is the highest level and the most expensive. Data
Sheet 7-45 explains SIS types and SIL ratings in more detail.)
The appropriate or “target” SIL rating for an SIS is normally established based on a site-specific hazards
analysis and through use of quantitative risk methods with defined risk reduction targets for a given location.
Without precluding this formal approach to SIL determination, this data sheet recommends a minimum SIL
1 rating based on FM Global evaluation of representative non-SIL-rated ESD designs in current use, and
taking into account the potential consequences of ESD failure to prevent a release inside high-value
manufacturing and warehouse buildings.
The overall likelihood of an uncontrolled release is considered to be relatively low with non-SIL-rated ESD
systems designed in accordance with current industry practice and that otherwise meet the criteria in Section
2.9.5.5, but the potential property damage due to fire and explosion can be severe if the ESD fails. On this
basis, the SIL 1 rating is recommended for locations where dispenser RFOs and building volumes are in
accordance with Table 2 in this data sheet. (If other hazardous processes in the area of the dispenser use
safety instrumented systems with SIL ratings higher than 1, then a formal SIL analysis is warranted to
determine the appropriate SIL for the dispenser ESD).
Meeting a SIL rating requires the SIS to be designed in compliance with a complex standard (IEC 61508).
The SIL certification process entails a detailed review and analysis of the SIS design, including field failure
data for components, PES software design, documentation of proof-testing procedures, component
replacement and maintenance procedures, and personnel competencies and other important human factors.
To ensure full compliance, independent certification of the SIL rating by FM Approvals is also recommended.
Contact FM Approvals for further information on their SIL certification service for safety systems:
information@fmapprovals.com
In summary, an FM Certified SIL 1 rating is recommended for the hydrogen dispenser ESD system because
it provides the following advantages over a non-rated or non-certified ESD:

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• Achieves a reasonable level of ESD performance that is quantifiable based on a recognized international
standard.
• Helps ensure proper performance management over the complete lifecycle of the dispensing system.

3.8.3.2 Restrictive Flow Orifice (RFO)

The restrictive flow orifice (see Figure 3) is a fixed, passive device that restricts the flow rate into the building
in the event of a break or leak in the inside piping. The maximum flow rate (based on physical limitations
imposed by the orifice diameter) is selected to be as low as possible in order to limit the size of a potential
hydrogen gas cloud or flame jet that might form following an accidental release, but the flow rate must also
be high enough to allow the filling operation to be accomplished efficiently. The maximum allowable flow rate
for lift truck hydrogen dispensers is commonly set at 2.2 lb/min (1 kg/min).
As discussed below (Section 3.8.4), gas dispersion modeling indicates that a fire or deflagration could occur
even if an RFO is used to inherently limit the maximum possible flow rate as recommended in Table 2;
however, the RFO can significantly reduce the total amount of available hydrogen and therefore mitigate the
extent of damage compared to an “uncontrolled” release (without an RFO).

3.8.4 Damage-limiting Building Volume (DLBV)

Any ESD system, even a SIL-rated one, may fail to shut down the hydrogen flow in a large accidental release
situation. Furthermore, even with flow-limiting devices such as RFOs installed, flow rates may still be large
enough for some buildings to cause severe structural damage by over-pressure due to a deflagration. Figure
3 illustrates this situation for a simulated 2.2 lb/min (1 kg/min) hydrogen release inside an industrial
warehouse, which results in a flammable cloud at the ceiling. (Ignition of the hydrogen cloud is also likely
to result in operation of many ceiling sprinklers).
As an additional damage mitigation safeguard in case the ESD fails to shut down the flow of hydrogen, the
dispenser is recommended to be located insidea building that is large enough to reduce the explosion
overpressure to prevent major structural damage. This approach is the basis for the volume thresholds in
Table 2 called “damage-limiting building volume” (DLBV). These volumes were determined to be large enough
to limit the overpressure and extent of damage, assuming an RFO controls the flow rate as indicated in the
table. Explosion modeling assumptions are described in a paper by Bauwens and Dorofeev (see Section
4.0).

3.8.5 Emergency Exhaust Ventilation

A dedicated emergency exhaust ventilation system is recommended (in Section 2.9.5.6) for locations where
damage-limiting building volumes in accordance with Table 2 cannot be achieved. This ventilation can help
prevent accumulation of hydrogen and subsequent formation of a flammable cloud at ceiling level during
an accidental release. At the same time, to ensure safe hydrogen concentrations within the ventilation system,
the ventilation rate must be sufficient to keep the concentration below the lower explosive limit (4% by
volume). Other important factors in the design of the ventilation system are the location and number of exhaust
intakes to ensure full capture and removal of the escaped gas.

3.9 Loss History

Hundreds of losses involving lift trucks were reported to FM Global during a recent 20-year period. The vast
majority of these incidents have been the result of impacts, including collapse of racking, damaged process
equipment, broken service lines (water, electricity, and gas) and water damage from broken sprinkler
systems.
The causes of fire included the following:
• A forklift hit a gas line and the gas was ignited by the exhaust of the lift truck.
• An electrical spark ignited flammable vapor.
• Propane leaked from a fuel cylinder and ignited on the exhaust.
• A forklift ignited nearby waste paper.
• A drum containing diesel fuel was ruptured by a lift truck during transport and the fuel was ignited.

©1991-2015 Factory Mutual Insurance Company. All rights reserved.

7-39 Lift Trucks
Page 22 FM Global Property Loss Prevention Data Sheets

Fig. 3. CFD simulation of indoor hydrogen releases

4.0 REFERENCES

4.1 FM Global
Data Sheet 1-11, Fire Following Earthquakes
Data Sheet 5-1, Electrical Equipment in Hazardous Locations
Data Sheet 5-49, Gas and Vapor Detectors and Analysis Systems
Data Sheet 7-91, Hydrogen
Data Sheet 7-50, Compressed Gases in Portable Cylinders
Data Sheet 7-54, Natural Gas and Gas Piping
Data Sheet 7-55, Liquefied Petroleum Gas (LPG) in Stationary Installations

4.2 Other
American Society of Mechanical Engineers (ASME). Hydrogen Piping and Pipelines. ASME B31.12-2008.
Bauwens, C.R., and S.B. Dorofeev. “CFD Modeling and Consequence Analysis of an Accidental Hydrogen
Release in a Large Scale Facility.” International Conference on Hydrogen Safety, 9-11 September 2013,
Brussels.

©1991-2015 Factory Mutual Insurance Company. All rights reserved.

Lift Trucks 7-39
FM Global Property Loss Prevention Data Sheets Page 23

Compressed Gas Association (CGA). Hydrogen Vent Systems. CGA G-5.5-2014

European Industrial Gas Association (EIGA). Gaseous Hydrogen Stations. IGC Doc 15/06/E.
National Fire Protection Association (NFPA). Hydrogen Technologies. NFPA 2.
National Fire Protection Association (NFPA). National Electrical Code. NFPA 70.
National Fire Protection Association (NFPA). Powered Industrial Trucks Including Type Designations, Areas
of Use, Conversion, Maintenance, and Operations. NFPA 505.
SAE International. Compressed Hydrogen Surface Vehicle Refueling Connection Devices, J2600, October
2002.
SAE International. Fueling Protocol for Gaseous Hydrogen Powered Industrial Trucks, J2601-3, June 2013.
International Electrotechnical Commission (IEC). Functional Safety of Electrical/Electronic/Programmable
Electronic Safety Related Systems. IEC EN 61508.

APPENDIX A GLOSSARY OF TERMS

FM Approved: Products and service that have satisfied the criteria for Approval by FM Approvals. Refer to
the Approval Guide for a complete list of products and services that are FM Approved.
Ignitable liquid: Any liquid or liquid mixture that is capable of fueling a fire, including flammable liquids,
combustible liquids, inflammable liquids, or any other term for a liquid that will burn. An ignitable liquid is one
that has a fire point.

APPENDIX B DOCUMENT REVISION HISTORY

October 2015. A new section was added to address safeguards for indoor fueling of lift trucks powered by
hydrogen fuel cells (Section 2.9).
July 2014. A new section was added to address safeguards for indoor dispensing of lift trucks powered by
hydrogen fuel cells (Section 2.9).
July 2013. Minimum separation distance was revised in recommendations 2.1.2.1 and 2.1.2.2.
October 2011. The following changes have been made:
A. Changed the title of the data sheet to better reflect the scope.
B. Added recommendations for hydrogen-powered and compressed natural gas-powered industrial trucks.
C. Added information on ventilation requirements for battery-charging areas.
D. Changed the guidance for areas where multiple batteries are charged; a cutoff room is now
recommended.
E. Added recommendations for operator training, and certification of equipment after repair by certified
technicians.
January 2000. The document has been reorganized to provide a consistent format.
February 1991. The document was completely revised.

©1991-2015 Factory Mutual Insurance Company. All rights reserved.