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2nd International Hydrogen Conference on Hydrogen Safety.San Sebastián, Spain – 11.-13. Sept. 2007.
Hydrogen Safety.New Challenges based on BMW Hydrogen 7.
Christian MüllerAutomotive Functional Safety.
Hydrogen SafetyChristian MüllerBMW Group12.09.2007Page 2
BMW Hydrogen Safety.Outline.
– Introduction
– Hydrogen 7- Hydrogen System- Safety Concept- Functional and Crash Tests
– New Challenges- Parking in Enclosed Areas- Degrading Concept of a Mono-Fuel Car
– Outlook
Hydrogen SafetyChristian MüllerBMW Group12.09.2007Page 3
BMW Hydrogen 7.The Product Development Process.
Series Development
Qualification for H2 components and systems
First BMW H2 vehicle provided to users
Technical Goals Hydrogen 7
Hydrogen SafetyChristian MüllerBMW Group12.09.2007Page 4
BMW Hydrogen 7.Hydrogen Technology Features.
LH2-Storage System Vehicle H2-Powertrain
New components
Adapted components
Bi-fueled internal combustion engine
Adapted ignition systemHydrogen gas warning system
CFK strengthening in side frame
Control System
Boil-off-ManagementSystem
LH2 fuel tank system
LH2 coupling system
Digital Motor Electronics (DME)
H2 mixture generation system
Hydrogen SafetyChristian MüllerBMW Group12.09.2007Page 5
BMW Hydrogen 7.Hydrogen Protection Measures.
High reliability of operation
Fault-tolerant design
Safety functions
Warning
Fault Prevention
Fault Control & Damage Mitigation
Hydrogen SafetyChristian MüllerBMW Group12.09.2007Page 6
BMW Hydrogen 7 Safety Features.Gas Warning System with H2 Sensors.
1....... Engine compartment2....... Passenger compartment3....... Rear shelf panel
4..... LH2 tank coupling5..... Barrier concept
A-D: Locking buttons at all doors, which display a flashing red light.
Hydrogen SafetyChristian MüllerBMW Group12.09.2007Page 7
BMW Hydrogen 7 Safety Features.System and Component Tests.
Hydrogen SafetyChristian MüllerBMW Group12.09.2007Page 8
BMW Hydrogen 7 Safety Features.Crash Tests.
FMVSS 30170% Offset right, 80 km/h
Car-to-Pole at tank coupling30 km/h
Hydrogen SafetyChristian MüllerBMW Group12.09.2007Page 9
Car-to-Pole at tank coupling30 km/hResult: no leakage from the H2 system.
FMVSS 30170% Offset right, 80 km/hResult: no leakage from the H2 system.
BMW Hydrogen 7 Safety Features.Crash Test Results.
Hydrogen SafetyChristian MüllerBMW Group12.09.2007Page 10
BMW Hydrogen 7 Safety Features.Crash Tests.
Truck overrideBarrier height 700 mm70 km/h (EES 45 km/h)
Hydrogen SafetyChristian MüllerBMW Group12.09.2007Page 11
BMW Hydrogen 7 Safety Features.Crash Test Results.
Truck override, Barrier height 700 mm, 70 km/h (EES 45 km/h)Result: no leakage from the H2 system.
Hydrogen SafetyChristian MüllerBMW Group12.09.2007Page 12
BMW Hydrogen 7 Safety Features.Vehicle Tests.
Tests throughout the year:
- High speed routes
- Testing in cold regions
- Testing in hot regions
> 1.4 million testing-kilometres
H2 technology - tested for the user.
Hydrogen SafetyChristian MüllerBMW Group12.09.2007Page 13
BMW Hydrogen – New Challenges.Parking in Enclosed Areas.
*Conservatively estimated critical value based on diffusion experiments with up to 600g/h (Source : Dr. Michael Swain, University of Miami, in 1998) H=2,19 m
H=2,11 m
B=2,85 m L=5,8 m
Objective:Unrestricted parking in enclosed
areas.
H2 limits to be controlled:
Normal Case < 5 g/hBoil Off < 20 g/hUncritical amount <
200 g/h
Critical amount > 200 g/h*
Hydrogen SafetyChristian MüllerBMW Group12.09.2007Page 14
BMW Hydrogen – New Challenges.Parking in Enclosed Areas.
Safety goal: Prevent severe injury due to emission of critical quantity of H2 in enclosed areas.
Risks
Requirements
Measures
H2-emission>> 200 g/h
critical H2
mixture in room
Ignition /explosion while
humans are exposed in
danger zone
Prevent emission of critical H2 quantity
Prevent formation of
critical mixture
Evacuate danger zone in time
- Vacuum stability
- Vacuum monitoring
- Delay H2 emission
- Generate emergency call
Warning (optical, acoustic, olfactory)
Hydrogen SafetyChristian MüllerBMW Group12.09.2007Page 15
BMW Hydrogen – New Challenges.Parking in Enclosed Areas.
* HySafe, InsHyde, HyGarage, NIP, …
Project Topics
- Parameter studies for H2 emission scenarios in vehicle environment
- Experimental studies of H2-diffusion in enclosed rooms.
- More detailed, realistic CFD models for garage types
- Conditions and consequences of an ignition.
- Quality criteria for garages.
funded projects*
We need to know
how to evaluate and classify the criticality of H2 air mixtures in different garage types, depending on
- rate and speed of emitted H2
- total amount of emitted H2
- position and geometry of H2 outlet
- garage size and architecture
- garage ventilation
Hydrogen SafetyChristian MüllerBMW Group12.09.2007Page 16
BMW Hydrogen – New Challenges.Degrading Concept of a Mono-Fuel Car.
Severi
ty o
f D
efe
cts
e.g. in case of a defective sensor
Request for service /
maintenance
e.g.: replacing defective
sensor
e.g. in case of icing of coolant heat exchanger
Functional degradation
e.g.: no fueling; reducing
engine power; no driving in
enclosed areasH2 alarm
in double barrier
Pre-warned shut-off
H2 alarm in
compartment
Immediate shut-off
Hydrogen SafetyChristian MüllerBMW Group12.09.2007Page 17
BMW Hydrogen – New Challenges.Outlook.
For a safe hydrogen future, we need …
- Common international standards for H2 safety technology
- clearly defined constraints for the vehicle environment
(public/private garages, fuelling stations, workshops …)
- Operationally tested, reliable automotive H2 components
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