Hydrogen Storage in Road Vehicles -

Regulations in Japan and Standards in the U.S.

Presented by Volker Rothe

StorHy final Event

3 June, 2008

Japanese Hydrogen Storage Regulations

• Scope

• Content

• Outlook

U.S. Hydrogen Storage Standard (SAE J2579)

• General Structure

• Guiding Principles

• Compressed Hydrogen Performance Requirements

Summary

Topics

Containers & Components（High Pressure Gas Safety Law）

Vehicle: Road Transportation Vehicle Law

(1) High Pressure Hydrogen Container

(3) Safety Valve（PRD)

(2) Stop Valve

Receptacle

Pressure Regulator

Scope of High Pressure Gas Safety

Law

Schematic View of Vehicle（Fuel Cell Vehicle）

Regulation:(1) High Pressure Hydrogen Containers JARI S 001(2) Stop Valve & (3) Safety Valve（PRD) JARI S 002

Hydrogen

Containers

Hydrogen

Air

FC StackMotor

Water

Scope of Regulations in Japan

Current Standards Situation in Japan

Current Japanese Technical Standards(JARI S 001 & S 002) have already been applied as regulations since March 2005.

JARI S 001(2004)Technical Standards for Containers for Compressed-Hydrogen Vehicle Fuel Device

JARI S 002(2004)Technical Standards for Components (valve and PRD) for Compressed-Hydrogen Vehicle Fuel Device

Scope VH3-Container and VH4-Container are permittedMinimum rupture pressure Stress ratio : 2.25Materials SUS316L, A6061T6

Maximum filling pressure shall be 35 MPa or less Container Inspection

Internal cubic capacity shall be 360L or less

Room Temperature Pressure Cycle Test

The test shall be carried out by shuttling between pressure of up to 2 MPa and pressure equal to or greater than 125% of the maximum filling pressure

Bonfire Test in Design Confirmation Test

The gas filled into the container shall be hydrogen gas

Gas Permeation Test in Design Confirmation Test

The rate of hydrogen gas permeation is less than 2 cm3 per hour per liter of container internal cubic capacity

Hydrogen Gas Cycle Test pressure shall be added at least 1,000 times

Outline of Technical Standard JARI S001

Necessity of Japanese Standards Revision

JARI S 001 & S 002 are standards for initial introduction of FCVs to the market.But it is necessary to consider the revision for future mass production of FCVs.

1) Light-weight and Low-cost high-pressure hydrogen containers and components are necessary.

2) Expansion of designated materials is necessary.(In Japanese case, the current standards limit the materials that can be used in high-pressure hydrogen environment)

3) Finally standardization of material evaluation methods is necessary.

Concepts of New Standard for Containers

1) To change the maximum working pressure from 35MPa to 70MPa.

2) To consider the Vehicle usage, Lifetime, Load conditions and Prospective Performance.

a) To change the pressure cycling test condition reflected the FCV cruisingdistance as a result of prospective performance and lifetime.

b) To change the extreme temperature cycling test condition reflected actuallow and high temperature (under high speed hydrogen supply and fast filling).

3) To guarantee the Container strength after Durability testsreflected Vehicle usage and Lifetime.

a) To change the cycle numbers and condition of burst pressure test.b) To execute the sequential loading tests.

Draft Schedule for International Harmonization

CY2007 CY2008 CY2009 CY2010 CY2011 CY2012

Japanese New Standards

SAEJ2579

ISO15869

gtr

Data Acquisition of metal materialsTechnical Normsfor material

Issue

Issue?

Issue

Collaborate with SAE using each data-based

Propose 3rd DIS with SAE

Establishment of GTR

Draft

Harmonization

Data Acquisition for container@JARI

Data Acquisition @PLI

TIR

3rd DIS

SAE J2579 Technical Information Report

Fuel Systems in Fuel Cell & Other Hydrogen Vehicles

Work on motor vehicle hydrogen storage system code initiated in SAE Fuel Cell Safety Work Group in 2003.

Active participation by fuel cell vehicle and storage system manufacturers and testing organizations, including representation from Asia, Europe and North America.

Existing codes including NGV2, EIHP, FMVSS 304 and CSA B51 considered, with focus to develop design-independent performance-based code.

SAE J2579 balloted in late 2007 and published as Technical Information Report (TIR) in January 2008.

Two-year period for evaluation testing and workplan items with goal to publish SAE J2579 as Recommended Practice in early 2010.

Background

Pro

babi

lity

Demand Distribution(Simulate Exposures in Field)

Capability Distribution• Hydrogen• Extreme Ambient Temperatures• Pressure and Temperature Cycles• Extended Static Pressure Holds• Production and Handling Damage • Chemical exposure• Penetration and Fire

Severity of Exposure

Verification of Compressed HydrogenStorage System Performance

Container Vessel

ContainerIsolation

Valve

FillCheckValve

ExcessflowReceptacle

with check

Full SystemIsolation

LowPressureRegulator

PRV PRV

HighPressureRegulator

Downstream Hydrogen Piping for delivery to Fuel Cell

System or Engine

PRD

ServiceDefuelShufoff

vent

Compressed Hydrogen Containment System

Includes all components and parts that form the primary pressure boundary

for stored hydrogen

Isolates stored hydrogen from --

• the remainder of the fuel system

• the surrounding environment

Typical Compressed Hydrogen System

No single-point failure should cause unreasonable risk to safety or uncontrolled vehicle behavior:

Fail-safe design

Isolation and separation of hazards to minimize cascading of events

Fault management with staged warnings and shutdowns

Isolation and containment of stored hydrogen is required to practice fault management on hydrogen and fuel cell vehicles.

Principle of “Design for Safety”

Section 5.2 – Compressed Hydrogen Storage System Performance Requirements

Expected service performance test sequence (pneumatic pressure cycling)

Durability performance test sequence (hydraulic pressure cycling)

Performance under service-terminating conditions

Content

a System equilibration @ -40oC 5cy +20oC fuel; 5cy <-35oC fuelb System equilibration @ +50oC 5cy <-35oC fuelc Service defuel rate >50cy

Prod

uctio

n Pr

oof P

ress

ure

150%NWP

25%cy -40oCa

25%cy +50oCb,c

125%NWP

180%NWP30 sec (hydr.)

500hr+85oC

500hr+85oC

25%cy +50oC25%cy -40oC 125%NWP

Pres

sure

Leak

/Per

mea

tion

time

125%NWP

Leak

/Per

mea

tion

Expected Service (pneumatic)

BurstBurst <20%

Durability Cy125%NWP

30 sec180%NWP

10cy Tamb150%NWP

150%NWP

Proo

f Pre

ssur

e

Pres

sure

Flaw

s &

Che

m

Dro

p

time

burstburst <20%

48hr125%NWP

Durability Performance (hydraulic)

Bonfire No burst & controlled PRD release

Penetration No burst

Burst Pressure

Cycle Life

Manufacturer will establishnew-vessel burst pressure and cycle life criteria

Service Terminating Conditions

System-level performance code that is independent of storage system design.

Uses two sequences of tests (expected service and durability performance) rather than discrete testing of virgin tanks.

Specifies end-of-life (EOL) burst margins rather than beginning-of-life (BOL) burst margins.

In addition to requiring EOL burst margin to be at least 1.8 times maximum working pressure, also requires EOL burst pressure to be at least 80% of virgin-tank burst pressure.

Includes pneumatic cycling and sustained stand time (in expectedservice sequence).

Key Distinctions from other Pressure Vessel Codes

Complete validation testing, and revise SAE J2579 as appropriate based on findings.

Develop localized fire test procedure(s) and performance criteria for possible inclusion in SAE J2579.

Consider refinements to specific provisions based on additional data analyses:Permeation requirementsNumber of pressure cyclesHold times and temperatures

Criteria for redesign not requiring re-qualification.

Re-qualification for additional service.

Criteria for allowing parallel (versus series) performance testing

Workplan for 2008 and 2009

JARI S 001 has almost same concept as ISO 15869.2 for Hydrogen Containers. Both of them have been derived from CNG standards.

Revision expected to cover 70 MPa and a wider material range

SAE J2579 provides performance based system level requirements to assess hydrogen storage safety while also facilitating future improvements in technology.

Validation testing scheduled for completion during 2008.

Summary

Thank you !