Design Optimization of Vanity Cover for Hydrogen Engine for Product Safety Health Assessment (PSHA) Compliance using CFD

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. 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 improvement in ventilation pathways, strategic placement of vent holes, and internal flow management to minimize localized hydrogen buildup. The final design achieved hydrogen concentration, which was less than 4% satisfying the Product safety 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.