Design of fuel cell systems laboratory for hydrogen, carbon monoxide and hydrocarbon safety

•Structured methodology used for fuel cell lab safety design and implementation.•CFD analyses aided in ventilation system design and gas sensor placement.•Human-independent control system implemented for reliability.•Implemented design is modular and scalable.

As research and development efforts in the area of fuel cells and hydrogen based energy accelerate, a large number of accidents have occurred in research laboratories. In this context, a design methodology for a simple, scaleable, modular and human-independent system for hydrogen, carbon monoxide and hydrocarbon safety in research laboratories is valuable. We have designed, developed and operationalized such a system in a pre-existing generic laboratory space. In this paper, we provide details of the mechanical, electrical and control aspects of this laboratory. We use CFD analysis to design a ventilation system, and to locate gas detectors for optimum detection time. The gas detectors, actuators, a real-time controller and other electrical components are part of a safety monitoring system that continuously gathers information, processes this information and takes appropriate action to safeguard personnel and equipment in real time. This fully operational safety laboratory is now a University-level research hub for all fuel cell (and other energy related) research activities, and is also one of a kind in the region. We also expect that the experience gained in this endeavor will be useful to other researchers in building a safe workplace.