1. ISO 19880-1, Hydrogen Fueling Station and Vehicle Interface Safety Technical Report
Jesse Schneider, BMW (ANSI Convener)
Guy Dang-Nhu, Air Liquide (co-chair)
Nick Hart, ITM Power (WG 24 Secretary)
Katrina Groth, Sandia National Labs (WG 24 Safety Methodologies Subteam Co-Chair)
WG 24, ISO TC197 Presentation at ICHS 2015

2. ISO 19880-1 Scope: Hydrogen Station
Hydrogen production / delivery system
Compression
Gaseous hydrogen buffer storage;
Pre-cooling device;
Gaseous hydrogen dispensers.
FCEV Vehicle Interface

3. ISO TR 19880-1 Overview General design & maintenance requirements
Equipment & components
Hydrogen and Electrical Safety
Layout & safety distance description
Safety Methodologies
Fueling protocol & interface Hydrogen Dispenser FCEV Testing 
Quality control
Alignment of Pressure Terminology and Values

4. ISO TC 197 WG 24 Team Structure with subteams
WG 24 Management
Schneider (US), Dang-Nhu (FR)
Hart (UK)
Hydrogen Station Acceptance
Moulthrop (US), Elliger (DE)
Safety Distance
Methodology
Flynn (FR), Groth (US)
Hydrogen Quality
Control
Tomioka (JP), Boisen(DK)
Hydrogen Fueling Process
Risk Assessment
Zimmermann (DE)

5. ISO 19880-1 Chapter 7, Hydrogen Fueling Diagram

6. Station Acceptance Checklists
Content: Consensus Criteria Internal to WG 24 +
External References
HFS impact protection Example:

7. Station Acceptance Testing Device Guidelines
- On-site “Field test” before normal operation of station
- periodic - e.g. every year for verification of safety relevant PLC
HRS Performance
Hydrogen Gas Quality
Particle Measurement
Mass Transfer
Measurement
Existing Standard
No, Guidelines
Yes (ASTM)
Goal to test or verify (parameter)
p, T in vehicle tank
To collect sample gas
Particle identification
Verification of
mass transfer
Safety relevant for interface HRS-FCHV
YES No
Yes
min. requirement = part of ch. 12

9. ISO 19880-1 Annex B Testing with Hydrogen Station Test Apparatus
Table B.1: Dispenser function tests
Dispenser function Tests
F.A.T.
S.A.T.
Confirmation that tables are correctly programmed into PLC through software means.
Yes No
15 Fault Simulation Testing (see table B.2).
However Abort Signal to also be testing in both Factory Acceptance Tests (F.A.T.) and Site Acceptance Tests (S.A.T.)
9 Field Tests on Site including 1-2 top off from low start pressure (see table B.3.3.4).
Verification that Measured Fueling performance Parameter are within limits Gas Temperature Window, Flow Rate and Pressure targets are within bounds of Fueling protocol

10. US “HyStep” HSTA Example Safety and Performance Testing
Hydrogen Station Test Apparatus (From US DOE/Sandia/NREL)
SAE J2601 Testing to All Categories:
Three 77L Type IV Quantum tanks
3.1 kg H2 capacity at 70 MPa NWP
Allows for testing all SAE J2601
3kg/6kg/9kg
SAE J2799 Communications Test
Abort/ Halt
Data Loss then Abort and resume
ID Protocol
Protocol Version #
CHSS Volume
Receptacle Type
Fueling Command
Measured Pressure/ Temperature

11. Safety Methodology: H2 Fueling Risk Assessment
Lead: Lars Zimmermann (Germany) from Shell

12. Fueling Components Updated Cycle Requirements
A fueling assembly should consist of a breakaway device, a hose(s), a nozzle and connectors between these components.
Suitability of the fueling assembly components for the specified service conditions and cycle life should be demonstrated by type testing. Type testing to enable a rated pressure to MAWP could for example include:
a hydrostatic pressure test to 375 % NWP;
100,000 pressure cycles to 125 % NWP;
190 pressure cycles to 150 % NWP.

13. P-Member Survey results – Example: Status Clearance distances

14. Safety Distance Methodology: Quantitative Risk Assessment
Example of a risk-informed approach to safety distances
See ICHS Presentation:
“HYRAM – a methodology and toolkit for quantitative risk assessment of hydrogen systems”

15. Status and Path Forward
ISO TR passed P-Member ballot in October, 2015
ISO TC 197 WG 24 will complete the comment review and submit for publication to ISO in November, 2015.
International Standard ISO Planned to finish by the end of 2016.
ISO IS to be used as a basis for the EU Alternative Fuels Directive (replacing ISO TS 20100) for hydrogen stations in Europe (including the 400 recently announced in Germany) starting in

16. Informational: H2 Fueling & Quality Open Data Sharing Website with Reports
Ca Views/400 Data Downloads and Official Release is 10/19!

17. Questions ? (Hydrogen Fueling Infrastructure Developments) Europe:
Germany
Demo-project Clean Energy Partnership 15 public stations + 35 in process in 2016
400 Privately funded in planning until 2023
Scandinavian Countries
Scandinavian Hydrogen Highway,
10 public stations / 6 in process/ 15 planned for
Japan
100 stations planned until 2016+
1000 stations in discussion until 2025
California / US
ZEV Mandate 10 public station, /
45 more in process for 2016
(100 Total planned to 2020)
US/ East Coast
East Coast Hydrogen Highway evaluation (TBD)

18. ISO TS 20100ISO
Different Direction from previous ISO TS 20100:
Detailed guidance on hydrogen dispensing. Reference SAE J2601 as possible means of fueling.
More detailed guidance on the acceptance process (both safety and performance aspects)
Study into variation of existing safety distances used currently around the world
Issues trying to address:
Interaction between vehicle and dispenser – what is the minimum acceptable reliability of fueling control (Risk Assessment Approach).
Understanding of Limits on dispensing pressures internationally, specifically the EU – what is needed to enable station side component filling of a vehicle 125 % NWP (not possible in EU currently). Goal to raise PRV setting to 138% NWP.
Hydrogen quality – how to control quality without burdening stations with excessive, unnecessary analysis requirements (leading to creation of new WG 28 in ISO TC 197)
Safety distances – status and trying to find consensus on an approach that is suitable for countries where there are currently very different methodologies in place

19. Backup Slides

20. Dispensing Components and Fueling Protocol Pressure Mismatch
Some fueling protocols go to a pressure of 125% during filling, however European dispenser components only rated to 125 % NWP.
PRV needs to be set at the so-called “rated pressure” in Europe
In the EU, this precludes fueling to 125 % NWP where PRVs are used as the over-pressure protection in case of the dispenser basic control system failure

21. ISO 19880-1 Pressure Harmonization Table for fueling components
Pressure Class
NWP
(Nominal Working Pressure)
MOP
(Maximum Operating Pressure) Highest Normal Fueling Operating Limit
MAWP3
(Maximum Allowable Working Pressure) Minimum pressure to which component is rated
Highest permissible dispenser PSV set-point
ITP
(Integrity Test Pressure)1,2
1.00xNWP
1.25xNWP
1.38xNWP
1.50xNWP
H25
25 MPa
31.25 MPa
34.4 MPa
37.5 MPa
H35 4
35 MPa
43.75 MPa
48.1 MPa
52.5 MPa
H50
50 MPa
62.5 MPa
68.8 MPa
75.0 MPa
H70 4
70 MPa
87.5 MPa
96.3 MPa
105.0 MPa
 Notes:
The proposed test level matches the maximum pressure expected during PSV relieving.
Other test pressure may be required according to ISO 15,649 or national regulations
Component Rating needs to be valid at maximum and minimum allowable material temperatures
Pressures used in hydrogen fueling of Road Vehicles in ISO TR

22. External Informative References
Where ISO/ IEC references do not exist, WG24 has chosen select external references such as:
SAE
J2601 Fueling Protocols for Light Duty Gaseous Hydrogen Surface Vehicles
SAE J2799 Hydrogen Surface Vehicle to Station Communications Hardware and Software
ASTM
D Sampling of High Pressure Hydrogen and Related Fuel Cell Feed Gases
D Standard Test Method for Sampling of Particulate Matter in High Pressure Hydrogen

23. Example: D7650-13 Device in Use Particulate Sampling Device
D Mpa Device (HYDAC) used in Germany

24. Example: D7606-11 Device in Use HQSA Devices
D7606 HQSA 70 MPa Device
(California Weights and Measures)
CaFCP HQSA 35MPa Device
California Fuel Cell Partnership
Dispenser
Sampling
Adaptor
Containers
Sample Collection
End Users
Analytical
Methods D