U.S. Department of Transportation Changes to Accommodate H2 as an Alternative Fuel in Commercial Vehicles Quon Kwan & William Chernicoff U.S. Department of Transportation NHA Annual Hydrogen Conference 2008

Purpose  To document the changes needed to accommodate H2 as alternative fuel in commercial vehicles  Commercial vehicles  Truck with GVWR, GCWR, GVW, or GCW > 10,000 lbs  Van with > 8 passengers without compensation  Bus with > 15 passengers regardless of compensation

Roles & Responsibilities of DOT Agencies Research and Innovative Technology (RITA) does H2 research & demonstration National Highway Traffic Safety Administration issues (FMVSS) Federal Motor Vehicle Safety Standards Federal Motor Carrier Safety Administration issues (FMCSRs) Federal Motor Carrier Safety Regulations Federal Transit Administration administers bus programs, e.g., National Fuel Cell Transit Bus

H2 Uses in Commercial Vehicles Auxiliary power (i.e., refrigeration, lighting, and climate control) Propulsion power in local, urban fleets of delivery trucks and transit buses

Summary of DOT Changes to Accommodate H2 Commercial Vehicles Development of general guidelines for safe operation & maintenance of commercial vehicles using H2 Revisions to Federal Motor Carrier Safety Regulations (FMCSRs) Revisions to North American Standard (NAS) Inspection Procedures Revisions to NAS Out-of-Service (OOS) Criteria

Development of General Guidelines Background  Hitherto, no up-to-date general guidelines to assist fleet managers on H2 in commercial vehicles Last guidelines in 1998 by DOT/FTA  Intended as guidance in lay language for safe operation & maintenance of commercial vehicles using H2  Not intended as in-depth specifications for use by Original Equipment Manufacturers

Development of General Guidelines (contents)  Background – H2 use as a motor fuel, types of onboard H2 generation and storage  Properties – H2 properties posing potential hazards  H2 Systems On-board a Vehicle – gaseous and liquefied systems, high voltage systems, and H2 injection systems  H2 Fueling Facilities – gaseous and liquefied systems  H2 Vehicle Maintenance Facilities – gaseous and liquefied systems  Emergency Response – personnel assigned to vehicles with H2

Development of General Guidelines “Guidelines for Use of Hydrogen in Commercial Vehicles” FMCSA-RRT , November

Revisions to Federal Motor Carrier Safety Regulations (FMCSRs) Bases for Revisions  Potentially hazardous properties of H2 High flammability  Flammable range (4% LFL to 74% UFL)  Ignition energy (0.20 mJ) Undetectability by the unaided human senses  Odorless and colorless  H2 flames very low in luminosity

Revisions to Federal Motor Carrier Safety Regulations (FMCSRs) Bases for Revisions (cont’d)  Potential hazards of onboard H2 storage Compressed gas (5,000 – 10,000 psi)  To go several 100s of miles between fill-ups – store H2 as compressed gas Cryogenic liquid (- 423 O F)  To increase range, the energy density of H2 fuel has to be increased – store H2 as cryogenic liquid

Revisions to Federal Motor Carrier Safety Regulations (FMCSRs) Bases for Revisions (cont’d)  Commercial vehicles using H2 may operate at high voltage H2 fuel cells – 300 to 600 VDC Hybrid-electric drive systems – 200 to 300 VDC

Revisions to Federal Motor Carrier Safety Regulations (FMCSRs ) Revisions to FMCSRs  Add new FMCSRs to address potential hazards of H2 High flammability Undetectability by unaided human senses  Add new FMCSRs to address potential hazards of onboard H2 storage Compressed gas Cryogenic liquid  Add new FMCSRs to address potential hazards of high voltage

Revisions to Federal Motor Carrier Safety Regulations (FMCSRs)  Add new FMCSRs to address potential hazards of H2 High flammability  Labeling to facilitate hazard recognition  Protection against unintended releases of H2 fuel  Protection against unintended ignition  Driver awareness training

Revisions to Federal Motor Carrier Safety Regulations (FMCSRs)  Labeling to facilitate hazard recognition Vehicle exterior (SAE J2578) Fueling compartment or door Storage containers

Revisions to Federal Motor Carrier Safety Regulations (FMCSRs)  Protection against unintended releases of H2 fuel Dust cap on fueling connector Support for fueling connector Automatic shut-off if system fault Manual shut-off valve on tanks Main on/off switch isolates fuel in storage tanks

Revisions to Federal Motor Carrier Safety Regulations (FMCSRs)  Protection against unintended releases of H2 fuel (cont’d) Venting system for enclosed spaces & pressure relief devices Fuel tank certification & re-certification Protecting/shielding of fuel tanks from collision & road hazards Components compatible with & not embrittled by H2 No H2 fuel lines through passenger compartment

Revisions to Federal Motor Carrier Safety Regulations (FMCSRs)  Protection against unintended ignition of H2 fuel Grounding and bonding between fuel system &  Vehicle chassis  Dispenser during fueling Installing/shielding of fuel tanks from heat sources Venting of any hydrogen releases away from  Engine  Wheel wells Venting systems of metal construction No smoking or cell phone use during fueling

Revisions to Federal Motor Carrier Safety Regulations (FMCSRs)  Driver Awareness Training Potentially hazardous properties of H2 fuel Operation of onboard H2 fuel system H2 fueling operations Actions to take in an emergency

Revisions to Federal Motor Carrier Safety Regulations (FMCSRs)  Add new FMCSRs to address potential hazards of H2 Undetectability by unaided human senses  Onboard leak detection system  No. & location of sensors depend on fuel system design  Alarm & automatic shut- down if [H2] > preset threshold

Revisions to Federal Motor Carrier Safety Regulations (FMCSRs)  Add new FMCSRs to address potential hazards of compressed gas onboard storage of H2 (~ FMVSS 304) Labeling of fuel tank and system components Certification & recertification of the fuel tanks Pressure relief devices (PRDs) on fuel tanks Post-accident inspection

Revisions to Federal Motor Carrier Safety Regulations (FMCSRs) Add new FMCSRs to address potential hazards of cryogenic liquid onboard storage of H2  Labeling of fuel tank and system components  Certification & recertification of the fuel tanks (~ SAE J2343)  Pressure relief devices (PRDs) on fuel tanks  Venting diffuser output to < 20% LFL  Post-accident inspection

Revisions to Federal Motor Carrier Safety Regulations (FMCSRs) Add new FMCSRs to address potential hazards of high voltage  High voltage hazard labeling  No high voltage in passenger compartment  Ground fault protection  Live components behind labeled enclosures

Revisions to North American Standard (NAS) Inspection Procedures Bases for revisions  NAS Inspection Procedures cover safety-critical parts & accessories on commercial vehicles  Fuel system is a safety-critical item  Revisions in FMCSRs affecting fuel system should follow through to revisions in NAS Inspection Procedures covering fuel system

Revisions to North American Standard (NAS) Inspection Procedures Types of inspections  Annual Most thorough and comprehensive Conducted by officer/inspector  Trip Cursory Conducted by employee before “run”  Roadside Thoroughness at discretion of officer/inspector Conducted at traffic stop or weigh/inspection station

Revisions to North American Standard (NAS) Inspection Procedures Revisions  Add to NAS Annual Inspection, checks for: Proper labeling to facilitate hazard recognition Protection against unintended H2 releases Protection against unintended H2 ignition Protection against potential hazards of onboard storage of H2 Driver awareness training (if driver present)

Revisions to North American Standard (NAS) Inspection Procedures Revisions  Add to NAS Trip or Roadside Inspection, checks for: Verifying that the annual inspection was performed Proper labeling to facilitate hazard recognition Visible damage to the H2 storage tanks Properly functioning leak detection system as well as any leaks Driver awareness training (if driver present)

Revisions to North American Standard (NAS) Out-of-Service (OOS) Criteria Bases for Revisions  Certain safety-critical items may be found so defective from inspection that they justify (OOS) status.  Changes in NAS inspection procedures warrant changes in NAS OOS Criteria  Leaks in fuel system warrant taking the vehicle OOS  NAS OOS Criteria need to consider H2 fuel leaks undetectable by unaided human senses

Revisions to North American Standard (NAS) Out–of-Service (OOS) Criteria Revisions  Add to the OOS Criteria, the following: Leak detected by onboard leak detector Leak detected by noise or H2 detector and confirmed by a “soap bubble test” Leak that vaporizes in the air A commercial vehicle using a H2 as an alternative fuel  Without leak detection system or  With defective leak detector

Acknowledgements Contractors  Booz Allen & Hamilton  M J Bradley & Associates Site visits and discussions  AC Transit  Santa Clara VTA  Sunline Transit  United Parcel Service  California Highway Patrol  California Fuel Cell Partnership  Daimler-Chrysler

Contact Information Quon Kwan U.S. Department of Transportation Federal Motor Carrier Safety Administration William Chernicoff U.S. Department of Transportation Research and Innovative Technology Administration

Background President’s Hydrogen Fuel Initiative  Established by President Bush in 2003  Purpose – free U.S. from foreign oil imports

Revisions to North American Standard (NAS) Inspection Procedures Levels of inspections  I – detailed driver and vehicle inspection  II – driver inspection and walk-around vehicle inspection  III – driver only inspection  IV -- special one-time inspection for a particular item  V -- vehicle only inspection without a driver present  VI – enhanced Level I inspection for radioactive cargo

Energy Density of Various Fuels