safety of hydrogen powered industrial trucks, lessons learned and existing codes and standards gaps...
TRANSCRIPT
SAFETY OF HYDROGEN POWERED INDUSTRIAL TRUCKS, LESSONS LEARNED AND EXISTING CODES AND STANDARDS GAPS
ICHS Conference – Sept 2011 Aaron Harris - [email protected]
Agenda
Industrial 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 Generation
2. Outdoor Compression and High Pressure Storage
3. Indoor Dispensing
4. Battery replacement in existing electric forklifts
12
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 engine
Operational 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 Interface
Guidance for user interfaces
Regenerative BrakingRegenerative braking requirements
Conversion Kit
Coordinate 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 ®