EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 1 EU-HarmonHy Workshop, Brussels, 26 September 2005 HyApproval Handbook for Approval of H ydrogen R efuelling S tations Reinhold Wurster L-B-Systemtechnik GmbH

EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 2 EU-HarmonHy Workshop, Brussels, 26 September Project Summary Summary of main scientific and technical activities Emphasis on Safety-related tasks regarding HRS review and evaluate safety, codes & standards from existing projects establish safety matrix (RCS, safety studies, risk assessment criteria, etc.) establish best practices for safety develop: realistic accident scenarios and their likelihood/ max. credible total H 2 leaks and leak rates agree on required modeling tools and techniques for risk assessment and simulations finalization of HRS draft guideline started by EIHP2 (  WG11, ISO TC 197 ) prepare safety documentation for Handbook Safety-related tasks regarding Vehicle/HRS-interface general interface description data exchange between vehicle and HRS (SAE, ATEX --> one standard) refueling process, time, frequency, procedures, pressure levels, etc. define best practices, use FMEA

EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 3 EU-HarmonHy Workshop, Brussels, 26 September Project Summary (2) Summary of main scientific and technical activities Emphasis on Pre-normative research task –Prioritisation and detailing for scenarios/simulations of HRS component failures: »CGH 2 hose break/ nozzle/dispenser failure at 35MPa and 70MPa »LH 2 dispenser failure »CGH 2 discharge hose break from tanker at 25 MPa and LH 2 discharge hose break from tanker »at dedicated/ combined HRS »of 300kg/ 1,500kg/ 3,500kg onsite storage volume investigated with CFD if possible for 2 independent release and dispersion calculations and 2 independent combustion calculations

EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 4 EU-HarmonHy Workshop, Brussels, 26 September Project Summary (3) Summary of main scientific and technical activities Emphasis on Dissemination The HyApproval results will be communicated in a widespread dissemination activity including various workshops and publications. Target groups will be: »approval authorities »responsible ministries »fire brigades (European Fire Association) »hydrogen distributors »CEN, EIGA and ISO Cooperation with other EU projects HyApproval is closely interlinked to the following projects: »HySafe »HyFleet/CUTE and ECTOS »ZERO REGIO »CEP

EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 5 EU-HarmonHy Workshop, Brussels, 26 September “Traffic light” analysis Major Items ( to be addressed by HyApproval )Traffic light to be addressed Note Material and Component Characteristics and System Integrity : hydrogen system integrity (normal operation) Endurance: Lifecycles, re-qualification; aging Refueling: Operability and simplicity in operation, compatibility and safety of the fueling Intentional Hydrogen Releases: Purging, boil-off, permeation (incl. losses, e.g. connections) Controls and Display (incl. H 2 -sensors) Working Group 1: H 2, Vehicle and surroundings safety in normal use HyApproval investigates accident scenarios only

EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 6 EU-HarmonHy Workshop, Brussels, 26 September “Traffic light” analysis ( seen from an approval perspective ) Major Items ( to be addressed by HyApproval ) Traffic light to be addressed Note Material and Component Characteristics and System Integrity Damage tolerance, mechanical properties, road hazards exposure, hydrogen system integrity (post-crash) hose/ nozzle/ dispenser failure post-accident Crashworthiness Differences to today existing vehicles only applicable to refuelling stations Leakage Fire safety Protection, prevention Explosion Protection Pressure and fire explosion Emergency Medical Rescue: Marking and installation position of parts Controls and Display (incl. H 2 -sensors) Working Group 2: Vehicle and surroundings safety in crash situations and defects, damages, confined areas hose/ nozzle/ dispenser

EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 7 EU-HarmonHy Workshop, Brussels, 26 September Green-yellow items ( Reproduction of Handbook Contents - 1 ) Brief description of major items, i.e. Preliminary Table of Contents of HyApproval Handbook : 1.0Introduction 2.0Basics of hydrogen dispensing 3.0Hydrogen refuelling station best practises 3.1Construction Requirements for Gaseous Hydrogen Storage 3.1.1Site Selection and System Sitting 3.1.2Storage System 3.1.3Dispensing System 3.2Construction Requirements for Liquefied Hydrogen Storage 3.2.1Site selection & system sitting 3.2.2Storage system Under-ground storage systems Above-ground storage systems 3.2.3Dispensing system 3.3Operating Requirements for a hydrogen refuelling station facility 3.4Maintenance requirements for a hydrogen refuelling station facility 3.4.1Gaseous Hydrogen station 3.4.2Liquefied Hydrogen station

EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 8 EU-HarmonHy Workshop, Brussels, 26 September Green-yellow items ( Reproduction of Handbook Contents - 2 ) 4.0Definition of the minimum requirements concerning hydrogen refuelling station lay out 4.1Industrial (or non-public access) 4.2Retailing (or public access) 5.0Vehicle requirements 5.1General requirements 5.2Grounding 5.3Instrumentation of the tank system 5.3.1Gaseous Hydrogen tank 5.3.2liquid Hydrogen tank 5.4Communication with the vehicle 5.4.1Gaseous Hydrogen tank system 5.4.2Liquid Hydrogen tank system 5.5Refuelling interface 5.5.1Gaseous Hydrogen for 35 MPa systems 5.5.2Gaseous Hydrogen for 70 MPa systems 5.5.3Liquid Hydrogen systems 5.6Driver training 5.7Others

EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 9 EU-HarmonHy Workshop, Brussels, 26 September Green-yellow items ( Reproduction of Handbook Contents - 3 ) 6.0Codes and Standards Affecting Design, Installation, Operation & Maintenance of a hydrogen refuelling station 6.1Hydrogen production 6.2Hydrogen storage 6.3Dispensing Facility 6.4Overview 6.5Codes and Standards Tables 7.0Case Study : Uniformly accepted (virtual) refuelling station design and lay out 7.1Project Description 7.2Installation Type 7.2.1Hydrogen Storage System 7.2.2Hydrogen Transfer System 7.2.3Installation Operation & Maintenance 7.3Safety (or Isolation) distances & hazardous areas 7.4Codes and Standards 7.5Additional Resources

EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 10 EU-HarmonHy Workshop, Brussels, 26 September Green-yellow items ( Reproduction of Handbook Contents - 4 ) 8.0Country specific issues France, Italy, Germany, The Netherlands, Spain, China 8.x.1Responsible bodies 8.x.2Information flow chart 8.x.3Authorities feedback 9.0Available safety cases

EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 11 EU-HarmonHy Workshop, Brussels, 26 September Proposals (max 3-4 slides) In addition to Safety items, a further list of other RCS items may be suggested, such as, for example: Modelling & validation of testing procedures (selection of test benchmarks to be compared against modelling)  see CFD modelling below Fuel quality, fuel standardisation/ certification (+ e.g. “green hydrogen” labelling) Refueling connection device Potential pre-normative research needs for the specific fields of the project: – standardisation of scenario calculations/ simulations, e.g. consensus based CFD modelling/RA/QRA input/ output parameter definition/standardisation (via GCG) – standardisation of vehicle refuelling (nozzle-receptacle) including data interface - one standard per fuel and pressure – standardisation of refuelling procedure (in coordination with SAE and CaFCP)