SAFETY OF HYDROGEN POWERED INDUSTRIAL TRUCKS, LESSONS LEARNED AND EXISTING CODES AND STANDARDS GAPS

ICHS Conference – Sept 2011 Aaron Harris - aharris@nuvera.com

AgendaIndustrial Trucks

Codes and Standards

Safety Challenges

- Intro to FC powered Ind. Trucks

- Intro to C&S for Ind. Trucks

- Fundamental safety aspects

Comparison: Cars and Forklifts

Lessons Learned and Gaps

- How do they compare with cars?

- Where to go from here?

Hydrogen meets the end-user’s goals:

- Increase productivity

- Optimize floor space

- Optimize energy costs

- Improved corporate image

Proven fuel cell advantages: - Refueling vs. Recharging - Replace indoor battery charger with outdoor On-Site generation and storage - On-Site Generation = on-demand generation - “Green”, Retail brand names associated with national energy/security policies

Hydrogen Warehouse

~1500 vehicles~300,000 refueling events per year

Component Introduction

1. Onsite Hydrogen Generation2. Outdoor Compression and High Pressure Storage3. Indoor Dispensing4. Battery replacement in existing electric forklifts

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3

4

Safety Challenges Struck By and Crush Hazards

Tip over Regenerative Braking Distraction

Flammable Gas Release Battery Room vs. On board FC system Indoor Fueling

Hot Surfaces Exhaust

Release of Hazardous Energy High Pressure Gas Electric Circuits greater than 50V

Industrial Trucks associated with 57 fatalities in 2009.

Fuel Cell System Components Energy Storage – Batteries, Ultra-Caps Power Conditioning Electronics Regenerative Braking Dissipation H2 Detectors/ Proof of Ventilation Fuel Cell Stack and BOP Heat Exchangers Embedded Controls and Software

Fuel Cell Power System UL 2267IEC 62282-4

Codes and Standards –Ind. TrucksIndoor Dispenser

Refueling GuidelinesHPIT 2 and SAE J2601-3

VehicleNFPA 505UL 2267 UL 583ITSDF B56.1

Industrial Vehicle

350 Bar Fueling Receptacle/Nozzle Pair SAE J2600Fuel Cell Power System

(Battery Replacement)

Hydrogen Pressure System ComponentsCSA HPIT 1 - Cylinders, valves, fittings, tubing

Tank

Hydrogen Pressure SystemSAE J2919

Dispenser Component StandardsHGV 4.1 - Dispenser HGV 4.2 - HoseHGV 4.4 - Breakaway HGV 4.5 - Priority and SequencingHGV 4.6 - Manual ValvesHGV 4.7 - Automated Valves

Generator NFPA 2 H2 Quality – SAE, ASTM ISO 16110-1,2

InstallationNFPA 2NECASME 31.12HGV 4.10ISO 20100

Compression and StorageNFPA 2ASME BPVC - storageHGV 4.8 – compressors

Comparison of Cars and Forklifts

Automotive Hydrogen Use- 70-90 Million new cars/year- 4-7 kg storage , 300 miles/fill, 1-2 fills/week…- 8-10 kg per week per vehicle- 0.5 - 1 kg/day- 300-500 kg in 25 year life / vehicle- Current US Vehicle Fleet: 300-400 vehicles

Industrial Truck Hydrogen Use- 0.2 Million new industrial trucks/year- 1-2 kg storage, 15-20 fills/week… - 40 kg per week per vehicle- 3-4 kg/day- 4000 – 6000 kg in 10 year life/vehicle- Current US Vehicle Fleet: 1000+ vehicles

Function Industrial Truck Light Duty Vehicle

Storage 8hr Shift 300 miles

Power Peak power Optimized (idle and peak)

Weight Heavy is good Light is good

Hybrid Replaces battery Replaces engineOperational

Life <10yrs 20yrs

Environment Indoors (freezers) Outdoors

User Interface Separate Integrated

System Pressure 250 or 350 bar 700 bar

Similarities

Engineering Development - fuel cell/battery hybrid vehicle systems, high-pressure hydrogen storage, regenerative braking, “Fuel Cell Range Extenders”

Safety - storage vessel performance, leak detection strategies, impact detection strategies, refueling

Codes and Standards Gaps – end of life control, aftermarket, consumer product vs. industrial use

‘Niche’ to ‘Broad’ Market Comparison

Differences

Engineering Development - weight, tank size and pressure, power requirements, vehicle integration, indoor fueling

Safety – driver training, regulatory agency

Codes and Standards Gaps – use type 1 tanks, indoor refueling standards

Fuel Cell System ComponentsSAE J2615 – System PerformanceSAE J2572 – Fuel Consumption MeasurementSAE J2574 – General Vehicle SafetySAE J2617 – Stack PerformanceSAE J2574 – Design for Recycling PEM stacks

Codes and Standards - Automotive

StationRefueling Guidelines

SAE J2601

Automotive

Generator NFPA 2 H2 Quality – SAE, ASTM ISO 16110-1,2

Dispenser Component StandardsHGV 4.1 - Dispenser HGV 4.2 - HoseHGV 4.4 - Breakaway HGV 4.5 - Priority and SequencingHGV 4.6 - Manual ValvesHGV 4.7 - Automated Valves

InstallationNFPA 2NECASME 31.12HGV 4.10ISO 20100

Compression and StorageNFPA 2ASME BPVC - storageHGV 4.8 – compressors

Interface StandardsHGV 4.3 – Temperature Comp.

CAFCP StandardH2 Quality Measurement

Weight and Measures

Tank

Hydrogen Pressure SystemSAE J2579

Fuel Cell System Components Energy Storage – Batteries, Ultra-Caps Power Conditioning Electronics Regenerative Braking Dissipation H2 Detectors/ Proof of Ventilation Fuel Cell Stack and BOP Heat Exchangers Embedded Controls and Software

Fuel Cell Power System UL 2267IEC 62282-4

Codes and Standards –Ind. TrucksIndoor Dispenser

Refueling GuidelinesHPIT 2 and SAE J2601-3

VehicleNFPA 505UL 2267 UL 583ITSDF B56.1

Industrial Vehicle

350 Bar Fueling Receptacle/Nozzle Pair SAE J2600Fuel Cell Power System

(Battery Replacement)

Hydrogen Pressure System ComponentsCSA HPIT 1 - Cylinders, valves, fittings, tubing

Tank

Hydrogen Pressure SystemSAE J2919

Dispenser Component StandardsHGV 4.1 - Dispenser HGV 4.2 - HoseHGV 4.4 - Breakaway HGV 4.5 - Priority and SequencingHGV 4.6 - Manual ValvesHGV 4.7 - Automated Valves

Generator NFPA 2 H2 Quality – SAE, ASTM ISO 16110-1,2

InstallationNFPA 2NECASME 31.12HGV 4.10ISO 20100

Compression and StorageNFPA 2ASME BPVC - storageHGV 4.8 – compressors

Lessons Learned and Gaps No one would want to put a steel tank on a vehicle

Forklifts use batteries as the counterweight = steel tanks are feasible Steel tanks: low tech, low cost, fast fill w/o strict temp compensation

Niche markets will not grow faster than automotive 200 - Cars 1500 - Forklifts

Refueling cycles are not a concern Cars = 1800 cycles in 20 years Forklift = 10,000 cycles in 10 years

Refueling standards are sufficient for all vehicles Indoor Fueling Use of the same nozzle/receptacle

Lessons Learned and Gaps

User InterfaceGuidance for user interfaces

Regenerative BrakingRegenerative braking requirements

Conversion KitCoordinate standards for “conversion kit” for battery replacement

Drive OffRefueling “drive off “ prevention – approx. 1 event per 200,000 fuelings

Leak and Pressure Testing Consistent approach to leak and pressure testing – assembly and service

Lessons Learned and Gaps

Escapee Scenario Use of SAE J2600 Nozzle/Receptacle for two separately

regulated markets Forklift refueled at retail gas station Car refueled at warehouse or industrial truck fleet fueling

station

Cylinder HandlingDesign and manufacture only as good as the installation

Counting Fill CyclesCyclic fatigue concerns requires close monitoring of fill cycles on each tank

Decommissioning Tanks At End of LifeRegulation and the aftermarket

Open Market Items

Government Policy/ Codes and Standards Interaction- Regulatory Parent Agencies and Involvement

- Industrial Trucks – OSHA – Dept of Labor- Automotive - FMVSS – Dept of Transportation

Codes and Standards Harmony and Implementation- Harmony - UL 583, UL 2267 and NFPA 505- Implementation – Comprehensive revision to UL2267 to reflect industry standards- Implementation – Interpretation issues with “new” separation distance tables in NFPA

Certification and Customer Confidence- Certification path not yet clearly defined- Hurdle for small companies to pursue certification of not yet proven product- Difficult for customers to trust uncertified products- Less diverse customer base (not as many enthusiasts)- Customers need gentle nudge to field new technology

F U E L C E L L S

EXPERIENCE

The Future of Energy ®