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All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

The NREL Sensor Laboratory: Status and Future Directions for Hydrogen Detection

The NREL Hydrogen Sensor Laboratory was commissioned in 2010 as a resource for the national and international hydrogen community to ensure the availability and proper use of hydrogen sensors. Since then, the Sensor Laboratory has provided unbiased verification of hydrogen sensor performance for sensor developers, end-users, and regulatory agencies and has also provided active support for numerous code and standards development organizations. Although sensor performance assessment remains a core capability, the mission of the NREL Sensor Laboratory has expanded toward a more holistic approach regarding the role of hydrogen detection and its implementation strategy for both assurance of facility safety as well as for process control applications. Active monitoring for detection of unintended releases has been identified by the NFPA 2 Storage Task Group as a viable approach for improving facility safety and lowering setbacks. The current research program for the Sensor Laboratory addresses both conventional and advanced developing detection strategies in response to the emerging large-scale markets, such as those envisioned by H2@Scale. These emerging hydrogen applications may require alternative detection strategies that supplement and may ultimately supplant the use of traditional sensors for monitoring hydrogen releases. Research focus areas for the NREL Sensor Laboratory now encompasses the characterization of released hydrogen behavior to optimize detection strategies for both indoor and outdoor applications, advanced methods of hydrogen leak detection such as hydrogen wide area monitoring approaches for large scale and distributed applications, the incorporation of active monitoring as a risk reduction strategy to improve safety at hydrogen facilities, and continuing support of hydrogen safety codes and standards. In addition to assurance of safety, detection will be critical for process control applications, such as hydrogen fuel quality verification for fuel cell vehicle applications and for monitoring and controlling of hydrogen-natural gas blend composition.

codes and standards↗
NASA NTRS2005

Hydrogen Sensors Boost Hybrids; Today's Models Losing Gas?

Advanced chemical sensors are used in aeronautic and space applications to provide safety monitoring, emission monitoring, and fire detection. In order to fully do their jobs, these sensors must be able to operate in a range of environments. NASA has developed sensor technologies addressing these needs with the intent of improving safety, optimizing combustion efficiencies, and controlling emissions. On the ground, the chemical sensors were developed by NASA engineers to detect potential hydrogen leaks during Space Shuttle launch operations. The Space Shuttle uses a combination of hydrogen and oxygen as fuel for its main engines. Liquid hydrogen is pumped to the external tank from a storage tank located several hundred feet away. Any hydrogen leak could potentially result in a hydrogen fire, which is invisible to the naked eye. It is important to detect the presence of a hydrogen fire in order to prevent a major accident. In the air, the same hydrogen-leak dangers are present. Stress and temperature changes can cause tiny cracks or holes to form in the tubes that line the Space Shuttle s main engine nozzle. Such defects could allow the hydrogen that is pumped through the nozzle during firing to escape. Responding to the challenges associated with pinpointing hydrogen leaks, NASA endeavored to improve propellant leak-detection capabilities during assembly, pre-launch operations, and flight. The objective was to reduce the operational cost of assembling and maintaining hydrogen delivery systems with automated detection systems. In particular, efforts have been focused on developing an automated hydrogen leak-detection system using multiple, networked hydrogen sensors that are operable in harsh conditions.

Source record↗
DOE OSTI2024

Hydrogen Leak Modeling for Development of Smart Distributed Monitoring Under Unintended Releases

Hydrogen is a versatile and clean energy carrier that can be produced from various renewable sources such as wind, solar, and hydropower. Hydrogen has the potential to play a crucial role in decarbonizing industrial processes that are currently reliant on fossil fuels and provide long-duration and/or seasonal energy storage to enable electricity decarbonization. Hydrogen can also be used as a fuel for fuel cell vehicles, providing a zero-emission alternative to traditional internal combustion engines. DOE launched the Hydrogen Energy Earthshot (Hydrogen Shot) in June 2021 to reduce the cost of clean hydrogen by 80% to $1 per 1 kilogram in 1 decade ("1 1 1"). While promising, Hydrogen is highly-flammable, and in the presence of oxygen, it can form explosive mixtures. . Therefore, understanding leak scenarios is essential to evaluate and mitigate the safety risks associated with potential hydrogen leaks. An increased understanding of leak behavior, and having tools to model leaks, can help assess how hydrogen would disperse in different environments, influencing emergency response plans and safety measures, and identify potential issues with materials and design systems that can withstand the challenges posed by hydrogen. Recently, researchers have attempted to study hydrogen leaks for development of risk management strategies. However, the focus has been on closed or semi-closed spaces like storage rooms, vehicles, garages, and fueling stations - all promising locations for future hydrogen infrastructure. In this presentation, the modeling environment extends the span of research further by modeling hydrogen leak in an outdoor, open space. We will present the key challenges with modeling hydrogen leaks in an uncontrollable environment, how they were handled, and how modeling results informed sensor selection and placement. A Hydrogen research facility at the National Renewable Energy Laboratory (NREL) was used as a case study to model hydrogen leaks. In the future, Hydrogen wide area detection methodologies will be developed and tested at this site to monitor for unintended and operational hydrogen releases. The data generated from modeling will be used to develop a predictive model to detect hydrogen leak location based on concentration measured by sensors in this open space. Furthermore, the facility was also chosen because controlled hydrogen releases can be performed. A computational fluid dynamics (CFD) based modeling approach was taken to model hydrogen leak. The full-scale hydrogen facility was modeled with a large ambient domain. The electrolyzer at the facility can produce a controlled release rate of 27 kg-H2/hr. Site-specific atmospheric and weather condition data such as wind direction, wind speed at various altitudes, and temperature were used as inputs to the model. To capture the variability of weather conditions, a subset of the weather conditions experienced during daytime hours without precipitation over the course of three months was generated; using established data clustering techniques, a total of 100 condition sets were chosen. The results show statistical distributions and ranges of hydrogen concentrations at locations throughout the domain. These distributions are compared to experimental data from a constant mass flow, controlled hydrogen release at the facility. The stochastic wind conditions of the release make direct validation difficult, therefore, statistical comparison approaches were used. Wind conditions are found to significantly impact the release behavior, including direction and concentration. Sensor selection and placement is proposed for the facility and is now based on release behavior predicted for the facility given its weather patterns; this is much more informed than without the modeling results. The methodology and analysis procedure can be translated to other facilities using modified geometries and site-specific weather conditions. Hydrogen holds great promise as a renewable energy fuel, but ensuring safety in its production, storage, and use is paramount. Studying potential leak scenarios in an open space will help develop sensors to detect hydrogen on a large spectrum of concentration and eventually build a smart distributed monitoring system.

CFD↗
NASA NTRS1993

Imaging Hydrogen Leaks With Raman Scattering

Proposed spectral imaging system used to detect leaking hydrogen from distance of 100 ft or more. Video cameras form images of leaking hydrogen by use of Raman scattering of laser beam from hydrogen. By indicating potentially explosive concentrations of hydrogen in air, system contributes to safety at facilities producing and handling hydrogen, such as fueling stations for hydrogen-burning automobiles of near future.

Mcdermid, Iain S.↗
DOE OSTI2021

Sub-second and ppm-level optical sensing of hydrogen using templated control of nano-hydride geometry and composition

Abstract The use of hydrogen as a clean and renewable alternative to fossil fuels requires a suite of flammability mitigating technologies, particularly robust sensors for hydrogen leak detection and concentration monitoring. To this end, we have developed a class of lightweight optical hydrogen sensors based on a metasurface of Pd nano-patchy particle arrays, which fulfills the increasing requirements of a safe hydrogen fuel sensing system with no risk of sparking. The structure of the optical sensor is readily nano-engineered to yield extraordinarily rapid response to hydrogen gas (<3 s at 1 mbar H 2 ) with a high degree of accuracy (<5%). By incorporating 20% Ag, Au or Co, the sensing performances of the Pd-alloy sensor are significantly enhanced, especially for the Pd 80 Co 20 sensor whose optical response time at 1 mbar of H 2 is just ~0.85 s, while preserving the excellent accuracy (<2.5%), limit of detection (2.5 ppm), and robustness against aging, temperature, and interfering gases. The superior performance of our sensor places it among the fastest and most sensitive optical hydrogen sensors.

36 MATERIALS SCIENCE↗
NASA NTRS1994

The development of a solid-state hydrogen sensor for rocket engine leakage detection

Hydrogen propellant leakage poses significant operational problems in the rocket propulsion industry as well as for space exploratory applications. Vigorous efforts have been devoted to minimizing hydrogen leakage in assembly, test, and launch operations related to hydrogen propellant. The objective has been to reduce the operational cost of assembling and maintaining hydrogen delivery systems. Specifically, efforts have been made to develop a hydrogen leak detection system for point-contact measurement. Under the auspices of Lewis Research Center, the Electronics Design Center at Case Western Reserve University, Cleveland, Ohio, has undertaken the development of a point-contact hydrogen gas sensor with potential applications to the hydrogen propellant industry. We envision a sensor array consisting of numbers of discrete hydrogen sensors that can be located in potential leak sites. Silicon-based microfabrication and micromachining techniques are used in the fabrication of these sensor prototypes. Evaluations of the sensor are carried out in-house at Case Western Reserve University as well as at Lewis Research Center and GenCorp Aerojet, Sacramento, California. The hydrogen gas sensor is not only applicable in a hydrogen propulsion system, but also usable in many other civilian and industrial settings. This includes vehicles or facility use, or in the production of hydrogen gas. Dual space and commercial uses of these point-contacted hydrogen sensors are feasible and will directly meet the needs and objectives of NASA as well as various industrial segments.

Liu, Chung-Chiun↗
NASA NTRS1993

Fiber-Optic System Would Detect Leaking Liquid H2

Proposed instrument based on optical time-domain reflectometry measures both locations and sizes of leaks in tanks and plumbing storing and transferring liquid hydrogen. Conceived for use in detecting leaks of hydrogen from propulsion system of Space Shuttle, concept applicable to detection of flammable and/or poisonous fumes in chemical-processing plants, fuel-distributing equipment, and other terrestrial applications.

Grove, Charles H.↗
NASA NTRS1993

The development of hydrogen sensor technology at NASA Lewis Research Center

The detection of hydrogen leaks in aerospace applications, especially those involving hydrogen fuel propulsion systems, is of extreme importance for reasons of reliability, safety, and economy. Motivated by leaks occurring in liquid hydrogen lines supplying the main engine of the Space Shuttle, NASA Lewis has initiated a program to develop point-contact hydrogen sensors which address the needs of aerospace applications. Several different approaches are being explored. They include the fabrication of PdAg Schottky diode structures, the characterization of PdCr as a hydrogen sensitive alloy, and the use of SiC as a semiconductor for hydrogen sensors. This paper discusses the motivation behind and present status of each of the major components of the NASA LeRC hydrogen sensor program.

Hunter, Gary W.↗
NASA NTRS1966

Sniffer used as portable hydrogen leak detector

Sniffer type portable monitor detects hydrogen in air, oxygen, nitrogen, or helium. It indicates the presence of hydrogen in contact with activated palladium black by a change in color of a thermochromic paint, and indicates the quantity of hydrogen by a sensor probe and continuous readout.

Dayan, V. H.↗
NASA NTRS2013

Ultrasonic Detectors Safely Identify Dangerous, Costly Leaks

In 1990, NASA grounded its space shuttle fleet. The reason: leaks detected in the hydrogen fuel systems of the Space Shuttles Atlantis and Columbia. Unless the sources of the leaks could be identified and fixed, the shuttles would not be safe to fly. To help locate the existing leaks and check for others, Kennedy Space Center engineers used portable ultrasonic detectors to scan the fuel systems. As a gas or liquid escapes from a leak, the resulting turbulence creates ultrasonic noise, explains Gary Mohr, president of Elmsford, New York-based UE Systems Inc., a long-time leader in ultrasonic detector technologies. "In lay terms, the leak is like a dog whistle, and the detector is like the dog ear." Because the ultrasound emissions from a leak are highly localized, they can be used not only to identify the presence of a leak but also to help pinpoint a leak s location. The NASA engineers employed UE s detectors to examine the shuttle fuel tanks and solid rocket boosters, but encountered difficulty with the devices limited range-certain areas of the shuttle proved difficult or unsafe to scan up close. To remedy the problem, the engineers created a long-range attachment for the detectors, similar to "a zoom lens on a camera," Mohr says. "If you are on the ground, and the leak is 50 feet away, the detector would now give you the same impression as if you were only 25 feet away." The enhancement also had the effect of reducing background noise, allowing for a clearer, more precise detection of a leak s location.

Source record↗
DOE OSTI2020

Thin Film Hydrogen Sensor Development, Testing and Integration Into Low Cost Wireless Sensing Systems (SBIR Phase 1 Final Report)

Element One, Inc. is reporting on the results of its DOE SBIR Phase I project for the development and testing of low-cost thin film hydrogen sensors and their subsequent integration into wireless sensing systems and networks. This work is based on Element One’s chemo-chromic sensing technology which indicates hydrogen presence (leaks) colorimetrically and electronically with no power required. The lack of required power makes them particularly suitable for passive Radio Frequency Identification Device (RFID) technology which can be deployed affordably and abundantly to detect leaks in hazardous environments. Element One built upon its experience with chemochromic materials that change color in the presence of hydrogen. Both thin films and pigments have been used, but thin films have the ability to change conductivity by more than three orders of magnitude making them ideal for resistive sensors. Prototype sensors were fabricated, tested and characterized. For the wireless component, Element One partnered with Esensor, Inc. to construct and test a wireless sensing network. The network was tested and validated at the National Renewable Energy Laboratory (NREL) in February and March. The tests involved exposing the wireless system to hydrogen gas concentrations of 1% and 5%. There were no significant problems encountered, and the system is ready for commercial development. The system demonstrated the viability of wireless hydrogen sensing networks for hydrogen leak detection and other applications.

08 HYDROGEN↗
NASA NTRS1976

Fluidic hydrogen detector production prototype development

A hydrogen gas sensor that can replace catalytic combustion sensors used to detect leaks in the liquid hydrogen transfer systems at Kennedy Space Center was developed. A fluidic sensor concept, based on the principle that the frequency of a fluidic oscillator is proportional to the square root of the molecular weight of its operating fluid, was utilized. To minimize sensitivity to pressure and temperature fluctuations, and to make the sensor specific for hydrogen, two oscillators are used. One oscillator operates on sample gas containing hydrogen, while the other operates on sample gas with the hydrogen converted to steam. The conversion is accomplished with a small catalytic converter. The frequency difference is taken, and the hydrogen concentration computed with a simple digital processing circuit. The output from the sensor is an analog signal proportional to hydrogen content. The sensor is shown to be accurate and insensitive to severe environmental disturbances. It is also specific for hydrogen, even with large helium concentrations in the sample gas.

Roe, G. W.↗
NASA NTRS2009

Chemochromic Hydrogen Leak Detectors

At NASA, hydrogen safety is a key concern for space shuttle processing. Leaks of any level must be quickly recognized and addressed due to hydrogen s lower explosion limit. Chemo - chromic devices have been developed to detect hydrogen gas in several embodiments. Because hydrogen is odorless and colorless and poses an explosion hazard, there is an emerging need for sensors to quickly and accurately detect low levels of leaking hydrogen in fuel cells and other advanced energy- generating systems in which hydrogen is used as fuel. The device incorporates a chemo - chromic pigment into a base polymer. The article can reversibly or irreversibly change color upon exposure to hydrogen. The irreversible pigment changes color from a light beige to a dark gray. The sensitivity of the pigment can be tailored to its application by altering its exposure to gas through the incorporation of one or more additives or polymer matrix. Furthermore, through the incorporation of insulating additives, the chemochromic sensor can operate at cryogenic temperatures as low as 78 K. A chemochromic detector of this type can be manufactured into any feasible polymer part including injection molded plastic parts, fiber-spun textiles, or extruded tapes. The detectors are simple, inexpensive, portable, and do not require an external power source. The chemochromic detectors were installed and removed easily at the KSC launch pad without need for special expertise. These detectors may require an external monitor such as the human eye, camera, or electronic detector; however, they could be left in place, unmonitored, and examined later for color change to determine whether there had been exposure to hydrogen. In one type of envisioned application, chemochromic detectors would be fabricated as outer layers (e.g., casings or coatings) on high-pressure hydrogen storage tanks and other components of hydrogen-handling systems to provide visible indications of hydrogen leaks caused by fatigue failures or other failures in those systems. In another type of envisioned application, chemochromic detectors of this type could be optoelectronically instrumented for monitoring to provide measured digital indications of color changes indicative of the presence of hydrogen.

Roberson, Luke↗
NASA NTRS1996

A Leak Monitor for Industry

GenCorp Aerojet Industrial Products, Lewis Research Center, Marshall Space Flight Center, and Case Western Reserve University developed a gas leak detection system, originally for use with the Space Shuttle propulsion system and reusable launch vehicles. The Model HG200 Automated Gas Leak Detection System has miniaturized sensors that can identify extremely low concentrations of hydrogen without requiring oxygen. A microprocessor-based hardware/software system monitors the sensors and displays the source and magnitude of hydrogen leaks in real time. The system detects trace hydrogen around pipes, connectors, flanges and pressure tanks, and has been used by Ford Motor Company in the production of a natural gas-powered car.

Source record↗
NASA NTRS2007

Effect of PdO on TiO(sub2) Loading on Chemochromic Detection of Hydrogen

Safety is always a concern in all applications that utilize hydrogen (H(sub2)) in one form or the other. Hydrogen leaks are invisible and odorless. In addition, blending odorants or additives into hydrogen in a manner similar to natural gas is generally undesirable for certain applications including proton exchange membrane fuel cells. To facilitate detection of the location of hydrogen leaks, a special chemochromic H(sub2) sensing material that employs titania (Ti0(sub2)) supported palladium oxide (PdO) pigments encapsulated within a special silicone matrix has been developed at the Florida Solar Energy Center (FSEC). Several batches of PdO H(sub2) sensing pigments were synthesized using various Ti0(sub2) supports and their hydrogen detection activity determined. TEM and Particle size distribution analysis showed that smaller particles with hemispherical crystalline structure produced faster coloration kinetics when exposed to H(sub2) gas. However, uniformly distributed PdO particles on the Ti0(sub2) surface displayed greater color contrast, quantified by delta epsilon measurements. XRD analysis indicated that the crystalline phase of Ti0(sub2) had no effect on the chemochromic performance of the pigments in laboratory environment.

Mohajeri, Nahid↗
NASA NTRS2006

Intelligent Chemical Sensor Systems for In-space Safety Applications

Future in-space and lunar operations will require significantly improved monitoring and Integrated System Health Management (ISHM) throughout the mission. In particular, the monitoring of chemical species is an important component of an overall monitoring system for space vehicles and operations. For example, in leak monitoring of propulsion systems during launch, inspace, and on lunar surfaces, detection of low concentrations of hydrogen and other fuels is important to avoid explosive conditions that could harm personnel and damage the vehicle. Dependable vehicle operation also depends on the timely and accurate measurement of these leaks. Thus, the development of a sensor array to determine the concentration of fuels such as hydrogen, hydrocarbons, or hydrazine as well as oxygen is necessary. Work has been on-going to develop an integrated smart leak detection system based on miniaturized sensors to detect hydrogen, hydrocarbons, or hydrazine, and oxygen. The approach is to implement Microelectromechanical Systems (MEMS) based sensors incorporated with signal conditioning electronics, power, data storage, and telemetry enabling intelligent systems. The final sensor system will be self-contained with a surface area comparable to a postage stamp. This paper discusses the development of this "Lick and Stick" leak detection system and it s application to In-Space Transportation and other Exploration applications.

Hunter, G. W.↗