Design Optimization of Hydrogen Engine Vanity Cover for PSHA Compliance using CFD leakage analysis

Abstract: The integration of hydrogen (H2) as a fuel source in internal combustion engines (ICE) necessitates stringent design measures to mitigate leakage risks and ensure operational safety. This study focuses on the design optimization of vanity cover for hydrogen engines which only serves the purpose for hiding fuel system, wire harness & engine aesthetic else there is no engineering function like sealing, load factor associated with it. This paper addresses the challenges and risks of using Vanity cover on Internal combustion engines, if fuel joints inside the cover start leaking and forms hydrogen cloud which if not ventilated or diluted properly will have safety risk considering low ignition of hydrogen. Computational fluid dynamics (CFD) analysis is carried out to assess and control hydrogen leakage through fuel rail connections, injector interfaces and associated high pressure fuel system components. Detailed modelling of hydrogen flow behavior, diffusion characteristics of leaked hydrogen are simulated for worst case scenarios. Design iterations targeted to improve ventilation pathways by strategic placement of vent holes, and internal flow management was done to minimize hydrogen accumulation. The final design achieved less than defined threshold H2 concentration for satisfying the Pre- Start Hazard Analysis (PSHA) threshold for hydrogen engines. This paper validates the critical role of CFD driven design methodology in proactively identifying leakage risks and optimizing component geometries for enhanced safety and regulatory compliance without compromising structural integrity or manufacturability. Key words: CFD - Computational Fluid Dynamics, H2 - Hydrogen, PSHA - Pre- Start Hazard Analysis, ICE - Internal Combustion Engines.