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Hydrogen-powered vehicles: Review of type-approval legislation on vehicle safety
Presented by Dinos VisvikisTechnical Lead – 14th April 2010
Objectives
Page 2
Investigate whether the type-approval directives and regulations on vehicle safety are compatible with hydrogen-powered vehicles
Examine certain issues identified in the hydrogen regulation (EC No. 79/2009):
- Hydrogen mixtures
- L category vehicles
Project overview
Page 3
Review type-approval directives and regulations on vehicle safety (M and N Category)
The use of mixtures of natural gas and hydrogen
Regulating the type-approval of L category vehicles
Task 1 - Literature review
Legislation
Industry standards
Scientific literature
Task 2 - Gathering information from
stakeholders
Legislators
Manufacturers
Test houses
Project overview
Page 4
Review type-approval directives and regulations on vehicle safety (M and N Category)
The use of mixtures of natural gas and hydrogen
Regulating the type-approval of L category vehicles
Task 1 - Literature review
Legislation
Industry standards
Scientific literature
Task 2 - Gathering information from
stakeholders
Legislators
Manufacturers
Test houses
EC type-approval of hydrogen vehicles
Regulation (EC) No. 79/2009 on type-approval of hydrogen-powered vehicles
- Amends certain annexes of framework directive (2007/46/EC)
- General requirements for approval of hydrogen systems and components
Detailed test procedures / specifications laid down in separate regulation (implementing measures)
- Draft regulation developed with hydrogen working group
Safety of hydrogen storage (and any components in contact with hydrogen)
Background
Page 5
EC type-approval of hydrogen vehicles
Vehicle must also comply with separate technical directives / regulations on vehicle construction
- EC directives or corresponding UNECE regulations
Vehicle safety directives will be repealed and replaced by general safety regulation (EC No. 661/2009)
- Reference made to UNECE regulation
Technical directives / regulations were developed for ICE vehicles
- Incompatible with hydrogen vehicles ?
Global technical regulation in development
Background
Page 6
Legislation reviewed by TRL
Page 7
Fuel tanks EMC
Frontal impact
Identification of controls
Side impact
Buses and
coaches
Page 8
Fuel tanks (and rear under-run)
Directive 70/221/EEC
Tanks for liquid fuel
Design and installation requirements
Performance requirements assessed by component-level tests
Rear under-run protection
Quasi-static force test
UNECE Regulation 34
Approval of vehicles: fuel tanks
Practically identical to directive
Approval of vehicles: prevention of fire risks
At request of manufacturer
Front / lateral /rear collision
Approval of tanks: separate units
Approval of vehicles: installation of approved tanks
Overview of type-approval legislation
Fuel tanks (and rear under-run)
Page 9
Fuel tank tests (70/221/EEC and Regulation 34)
- Hydraulic internal pressure test
- Overturning test
- Impact resistance
- Mechanical strength
- Fuel permeability
- Resistance to fuel
- Resistance to fire
- Resistance to high temperature
- Markings on the fuel tank
Overview of type-approval legislation
Plastic fuel tanks only
Fuel tanks (and rear under-run)
Page 10
Fuel tanks legislation inappropriate for hydrogen-powered vehicles
- Performance tests not designed for a fuel with the properties of hydrogen
Regulation (EC) No. 79/2009 and implementing measures establish requirements for hydrogen containers
Compatibility with hydrogen-powered vehicles
Hydrogen-powered vehicles should be exempt from fuel tanks legislation
- Under-run requirements still relevant
Outline proposals for amendments
Page 11
Radio interference (electromagnetic compatibility)
Directive 72/245/EEC
Electromagnetic compatibility of whole vehicles and electrical/electronic sub-assemblies
Immunity to radiated and conducted disturbances
Control of unwanted radiated and conducted emissions
Test methods reference CISPR and ISO standards
UNECE Regulation 10
Practically identical to directive
References later versions of CISPR and ISO standards
Overview of type-approval legislation
Radio interference (electromagnetic compatibility)
Page 12
Specifications for whole vehicles:
- Broadband electromagnetic radiation from vehicle
- Narrowband electromagnetic radiation from vehicle
- Immunity of vehicle to electromagnetic radiation
Specifications for electrical/electronic sub-assemblies (ESA)
- Broadband electromagnetic radiation from ESA
- Narrowband electromagnetic radiation from ESA
- Immunity of ESA to electromagnetic radiation
- Immunity of ESA to transient disturbances conducted along supply lines
- Emission of conducted disturbances from ESA
Overview of type-approval legislation
Radio interference (electromagnetic compatibility)
Page 13
No specific provisions for hydrogen-powered vehicles in type-approval legislation
- Fuel cell vehicles: electrical power train
Provisions made in some international standards
- E.g. CISPR 12: referenced for broadband emissions test method
Regulation refers to later versions of standards than directive
- E.g. Regulation - CISPR 12:2001+A1:2005
Directive - CISPR 12:2001
Regulation does not always refer to the latest version of the standard
- E.g. CISPR 12:2007+A1:2009
Compatibility with hydrogen-powered vehicles
Radio interference (electromagnetic compatibility)
Page 14
Emissions may be greater during acceleration/deceleration
- Not examined for type-approval
Antenna positions set for conventional vehicles
- E.g. relative to “engine” mid-point
Emission of conducted disturbances
- High power components potentially significant sources
- Maximum allowed pulse amplitude for 12 V and 24 V systems only
Compatibility with hydrogen-powered vehicles
Ruddle , A. R. (2002). Investigation of electromagnetic emissions from alternative powertrain road vehicles
(01-845060). Nuneaton, UK: MIRA
Radio interference (electromagnetic compatibility)
Page 15
Update type-approval legislation to refer to latest version of international standard
- May require more detailed changes (broadband / narrowband differentiation removed in some standards)
Testing under acceleration and deceleration
- Costs and benefits need to be understood
- Conventional vehicles may also exceed limits
New antenna positions ?
- Research needed to define new positions
Outline proposals for amendments
Page 16
Identification of controls, tell-tales and indicators
Directive 78/316/EEC
Mandatory identification:
Twenty-three symbols
Derived from ISO 2575:1982 (4th ed.)
Optional identification:
Eleven symbols
Derived from ISO 2575:1982 (4th ed.)
Any other symbol can be used for controls, tell-tales and indicators not listed in directive
UNECE Regulation 121
Location, identification and colour
Forty-two symbols
ISO 2575:2000 recommended for controls, tell-tales and indicators not listed in regulation
Any other symbol if not listed in regulation or ISO standard
Overview of type-approval legislation
Identification of controls, tell-tales and indicators
Page 17
Overview of type-approval legislation
Directive 78/316/EEC
Mandatory Optional
•Master light
•Dipped-beam headlamps
•Main-beam headlamps
•Side lamps
•Front fog lamps
•Rear fog lamps
•Headlamp levelling
•Parking lamps
•Direction indicators
•Hazard warning
•Windscreen wiper
•Windscreen wiper/washer
•Headlamp cleaning
•Windscreen demisting/ defrosting
•Rear window demisting/ defrosting
•Ventilating fan
•Diesel pre-heat
•Choke
•Brake failure
•Fuel level
•Battery charge
•Engine coolant temperature
•Parking brake
•Rear window wiper
•Rear window washer
•Rear window wiper and washer
•Intermittent windscreen wiper
•Horn
•Front hood (bonnet)
•Rear hood
•Seat belt
•Engine oil pressure
•Unleaded petrol
Regulation 121
•Master light
•Dipped-beam headlamps
•Main-beam headlamps
•Side lamps
•Front fog lamps
•Rear fog lamps
•Headlamp levelling
•Parking lamps
•Direction indicators
•Hazard warning
•Windscreen wiper
•Windscreen wiper/washer
•Headlamp cleaning
•Windscreen demisting/ defrosting
•Rear window demisting/ defrosting
•Ventilating fan
•Diesel pre-heat
•Choke
•Brake failure
•Fuel level
•Battery charge
•Engine coolant temperature
•Parking brake
•Rear window wiper
•Rear window washer
•Rear window wiper/washer
•Intermittent windscreen wiper
•Horn
•Front hood (bonnet)
•Rear hood
•Seat belt
•Engine oil pressure
•Unleaded petrol
•Power window lock
•Airbag malfunction
•Side airbag malfunction
•Passenger airbag off
•Antilock brake system malfunction
•Speedometer
•Engine malfunction
•Air conditioning system
•Automatic transmission
•Engine start
•Engine stop
•Brake lining wear-out
•Heating system
•Heating fan
•Odometer
•Low tyre pressure
Identification of controls, tell-tales and indicators
Page 18
No specific symbols for hydrogen vehicles in type-approval legislation
Directive 78/316/EEC permits any symbol (provided there is no danger of confusion)
Regulation recommends ISO 2575:2000 symbols are used
Current version is ISO 2575:2004 (+ A1:2005, A2:2006, A3:2008 and A4:2009)
- Fuel type
- Electric motor failure
- Electric motor enabled
- No regenerative braking symbols
Compatibility with hydrogen-powered vehicles
Identification of controls, tell-tales and indicators
Page 19
Compatibility with hydrogen-powered vehicles
Regulation (EC) No. 79/2009 requires automatic shut-off valve
- No specific requirement for driver warning / tell-tale
Draft implementing measures specify driver warning for boil-off management system failure
Draft implementing measures specify warning for failure of electronic vehicle control system
Draft global technical regulation specifies warning in event of hydrogen leakage or failure of detection system
- No symbol agreed
- Green for system working; amber/orange for malfunction of detection system; red for activation of emergency shut-off
Identification of controls, tell-tales and indicators
Page 20
Type-approval legislation should refer to the latest version of ISO 2575
- Currently ISO 2575:2004 (7th ed.), including amendments 1:2005, 2:2006, 3:2008 and 4:2009
- ISO 2575:2010 (8th ed.) expected soon
Type-approval legislation should include symbols for hydrogen vehicles
- Harmonised with Regulation (EC) No. 79/2009 and implementing measures
- Harmonised with (draft) global technical regulation
- Are new symbols understood by public ?
Outline proposals for amendments
Page 21
Frontal impact / Side impact
Directives 96/79/EC and 96/27/EC
Frontal impact:
Offset deformable barrier (ODB) at 56 km/h
Side impact:
Mobile deformable barrier (MDB) at 50 km/h
Occupant injury protection
Fuel system integrity
UNECE Regulations 94 and 95
Frontal impact:
ODB at 56 km/h
Air bag instructions
Side impact:
Progressive MDB at 50 km/h
EuroSID-2
Regulations more „up-to-date‟ than directives
Overview of type-approval legislation
Frontal impact / Side impact
Page 22
No provisions for hydrogen-powered vehicles
- Test set-up
- Performance requirements
Key issues:
- Fuelling options: hydrogen Vs helium / high pressure Vs low pressure
- Hydrogen leakage: measurement period / performance criteria
- Protection against electric shock (fuel cell vehicles)
Amendments in progress: „Group of interested experts on electric vehicles post-crash (EVPC) provisions‟
- Main focus is electric vehicles
Compatibility with hydrogen-powered vehicles
Frontal impact / Side impact
Page 23
Proposals for amendments
Harmonisation with draft global technical regulation
- Compressed gas: helium (90% nominal working pressure)
- Liquid: nitrogen (minimum mass equivalent of maximum quantity of liquid hydrogen in inner vessel)
- Post crash leakage limit: 118 NL/min (energy equivalent to conventional fuel)
Other considerations for Europe ?
Page 24
Buses and coaches
Directive 2001/85/EC
Design and fire protection requirements
Stability test:
28° overturning limit
Strength of superstructure:
One of four test methods
(Vehicle roll-over test / body section roll-over / pendulum test on body section / calculation)
No intrusion into defined space / no part of space projects outside deformed structure
UNECE Regulations 66 & 107
UNECE Regulation 66 (stength of superstructure) - same test as directive
UNECE Regulation 107 (general construction of M2 and M3
vehicles) - same design and fire protection requirements and stability test
Overview of type-approval legislation
Buses and coaches
Page 25
Main requirements and test methods are independent of power train
Stability test
- No specific reference to fuel condition – mass in running order
- Mass can be added
- Representative for roof-mounted containers ?
Strength of superstructure
- Complete vehicle test may be required
- Fuel and other explosive materials can be substituted
Compatibility with hydrogen-powered vehicles
Buses and coaches
Protection against fire risks
- The engine compartment:
Precautions against flammable materials contacting fuel or sources of heat
- Electrical equipment and wiring:
Manually-operated isolating switch capable of disconnecting all circuits from main supply wherever voltage exceeds 100 V RMS
- Batteries:
Broad requirements relating to battery location, installation and safety
Page 26
Compatibility with hydrogen-powered vehicles
Buses and coaches
Page 27
Minor amendments required to introduce hydrogen vehicles
Clarify whether electrical and battery requirements apply to electrical power train (fuel cell vehicles)
Additional electrical safety provisions may be needed (fuel cell vehicles)
- E.g. additional safety prescriptions for trolley buses in UNECE Regulation 107
Outline proposals for amendments
Project overview
Page 28
The use of mixtures of natural gas and hydrogen
Review type-approval directives and regulations on vehicle safety (M and N Category)
Regulating the type-approval of L category vehicles
Task 1 - Literature review
Legislation
Industry standards
Scientific literature
Task 2 - Gathering information from
stakeholders
Legislators
Manufacturers
Test houses
The use of mixtures of natural gas and hydrogen
Page 29
Natural gas trade-off: Emissions vs. efficiency
Potential benefits with 5-30% hydrogen (by volume)
Fuel is usually pre-mixed (i.e. off-board) and used in natural gas engines
Research focussed on combustion analyses and emissions
What are the safety implications ?
- Ignition properties of hydrogen are „different‟ to natural gas
NaturalHy project – Safety work package
- Hazards and risks of using natural gas infrastructure to deliver natural gas / hydrogen mixtures
- Up to 30% can be added without affecting risk to public significantly
State-of-the-art
The use of mixtures of natural gas and hydrogen
Page 30
Most current mixtures can be used in natural gas systems / vehicles
Hydrogen legislation may be too stringent for mixtures
Natural gas legislation may not deal with all the risks
Research is needed on the safety of hydrogen mixtures used in vehicles
Review of hydrogen regulation and implementing measures
In the absence of scientific information a „worst case‟ approach could be adopted
- The hydrogen regulation and implementing measures should apply
Outline proposals for amendments
Project overview
Page 31
Regulating the type-approval of L category vehicles
Review type-approval directives and regulations on vehicle safety (M and N Category)
The use of mixtures of natural gas and hydrogen
Task 1 - Literature review
Legislation
Industry standards
Scientific literature
Task 2 - Gathering information from
stakeholders
Legislators
Manufacturers
Test houses
Regulating the type-approval of L category vehicles
Page 32
Background
L category vehicles are part of a separate regulatory framework
- Two, three and some four wheel vehicles
- Light vehicles; max. speed ≥ 6 kph
No specific provisions for hydrogen-powered vehicles in framework directive (2002/24/EC)
- Provisions are made for electric vehicles
- Hydrogen vehicles might be outside the scope (Article 16.3)
An approval route may be possible if an equivalent level of safety and environmental performance can be demonstrated
- Other member states may not accept approval
Regulating the type-approval of L category vehicles
Page 33
State-of-the-art
L category vehicles are lighter and need less energy than larger vehicles
- Potential early adopters of hydrogen ?
Main developments so far: two-wheel, fuel cell vehicles
- Hybrid power-trains (fuel cell + battery)
Vehicles have been demonstrated
- FRESCO (FP5) - Fuel cell scooter
- HYCHAIN MINI-TRANS (FP6) - Several vehicles including: fuel cell scooter, small utility vehicle
- Suzuki Crosscage
- Intelligent Energy ENV
Regulating the type-approval of L category vehicles
Page 34
Review of hydrogen regulation
Articles 5 to 9 are independent of vehicle type and could be applied to hydrogen-powered L category vehicles
Article 10 (including Annex VI) on the installation of hydrogen components and systems includes potentially vehicle-specific requirements
- Protection against damage / isolation from heat sources
- Acceleration testing
- References to vehicle compartments , e.g.
- Container must not be installed in engine compartment
- Passenger compartment must be separate from hydrogen system
Regulating the type-approval of L category vehicles
Page 35
Regulation (EC) No. 79/2009 (Annex VI)
1. The hydrogen system must be installed in such a way that it is protected against damage. It must be isolated from heat sources in the vehicle
2. The hydrogen container may only be removed for replacement with another hydrogen container, for the purpose of refuelling or for maintenance. In the case of an internal combustion engine, the container must not be installed in the engine compartment of the vehicle.
5. The hydrogen container must be mounted and fixed so that the specified accelerations can be absorbed without damage to the safety related parts when the hydrogen containers are full.
11. The venting or heating system for the passenger compartment and places where leakage or accumulation of hydrogen is possible must be designed so that hydrogen is not drawn into the vehicle.
13. The passenger compartment of the vehicle must be separated from the hydrogen system in order to avoid accumulation of hydrogen. It must be ensured that any fuel leaking from the container or its accessories does not escape to the passenger compartment of the vehicle.
14. Hydrogen components that could leak hydrogen within the passenger or luggage compartment or other non-ventilated compartment must be enclosed by a gas-tight housing or by an equivalent solution as specified in the implementing measures.
16. Labels or other means of identification must be used to indicate to rescue services that the vehicle is powered by hydrogen and that liquid or compressed (gaseous) hydrogen is used.
Regulating the type-approval of L category vehicles
Page 36
Outline proposals for amendments
Amendments to L category framework directive (2002/24/EC) are needed to accommodate hydrogen vehicles
New technical requirements needed for hydrogen storage
- Hydrogen regulation (79/2009) and implementing measures could be amended for L category vehicles
- But; may be inappropriate to include L category - separate framework
- New regulation for hydrogen-powered L category vehicles could be developed
Individual type-approval acts also need to be amended to accommodate hydrogen fully
Thank you
Presented by Dinos VisvikisTechnical Lead – 14th April 2010
Tel: +44 (0) 1344 770393Email: [email protected]