1. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 1 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 Fuel Cell TEsting & STandardisation NETwork FCTESTNET Georgios Tsotridis - Andreas Podias EC-DG JRC - Institute for Energy

2. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 2 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 Contents: Network Objectives & Structure Project Summary of WP 1 Transport Applications Traffic Lights analysis Pre normative research needs

3. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 3 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 Project Summary / 1 NETWORK OBJECTIVES Compile already existing and further develop harmonised testing procedures and testing methodologies applicable to: stationary power sources;stationary power sources; portable fuel cells;portable fuel cells; transport applicationstransport applications Focusing on: single fuel cellssingle fuel cells fuel cell stacksfuel cell stacks fuel cell systemsfuel cell systems

4. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 4 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 FCTESTNET STRUCTURE WP 1 APPLICATIONSTRANSPORT WP 2 APPLICATIONSSTATIONARY WP 3 APPLICATIONSPORTABLE WP 4 BALANCE OF PLANTS WP 8 EXTERNALRELATIONS US, CANADA JAPANSTAND.BODIESIEA STEERING COMMITEE WP 0 COORDINATION DG-RTDDG-TREN (Advisory role) WP 5 PEMFC WP 6 MCFC WP 7 SOFC TechnologiesArea ApplicationsArea

5. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 5 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 Project Summary / 2 WP 1 of FCTESTNET focuses : on test procedures for the evaluation of fuel cell systems for the following transport application areas: Road vehicles Rail transport Marine applications Aviation

6. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 6 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 Project Summary / 3 The work performed in WP 1 has covered the following activities (1/2): Inventory of existing formal & ad-hoc test procedures; Analysis of operational conditions and requirements for fuel cell systems; Identification of a list of tests that are relevant for characterising fuel cell systems;

7. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 7 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 Project Summary / 4 The work performed in WP 1 has covered the following activities (2/2): Development of a number of test procedures where there is a high need of harmonization Identification of knowledge gaps and needs for future work

8. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 8 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 Project Summary / 5 More specifically, WP 1 has developed: a list of all tests relevant for road vehicle applications; a set of 9 Test Modules see next slides These tests might serve as input to standardisation bodies;

9. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 9 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 “Traffic light” analysis / 1 Major ItemsNote Environmental Test Programme Harmonisation areas Functional Test Programme automotive, marine, aviation Durability Test Programme automotive, marine, aviation Safety Test Programme automotive, marine, rail, aviation FCTESTNET - Work Package 1: Transport applications

10. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 10 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 “Traffic light” analysis / 1 Major ItemsTraffic lightNote Environmental Test Programme Harmonisation areas NOx emissions marine, aviation Variation of ambient conditions: cold start automotive, marine, aviation EMC tests automotive, marine, rail, aviation FCTESTNET - Work Package 1: Transport applications

11. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 11 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 “Traffic light” analysis / 2 Major ItemsTraffic lightNote Functional Test Programme Harmonisation areas Fuel consumption: fuel cell system on homologation cycle (H 2 fuel) automotive APU Voltage Regulation automotive, marine, rail, aviation Power quality: Transient response automotive, marine, rail, aviation FCTESTNET - Work Package 1: Transport applications

12. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 12 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 “Traffic light” analysis / 3 Major ItemsTraffic lightNote Durability Test Programme Harmonisation areas Dielectric strength marine, rail, aviation FCTESTNET - Work Package 1: Transport applications

13. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 13 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 “Traffic light” analysis / 4 Major ItemsTraffic lightNote Safety Test Programme Harmonisation areas Crash safety automotive, rail, aviation Overload and short circuit automotive, marine, rail, aviation FCTESTNET - Work Package 1: Transport applications

14. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 14 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 NOx emissions of fuel cell system NOx emissions are currently regulated in marine applications in various parts of the world. Due to these requirements, a fuel cell system is required also to conform to the existing limits. While in the automotive world hydrogen and low temperature fuel cells are being considered, the economics of the marine industry is likely to drive to the use of diesel fuels, also with fuel cell systems. This requires onboard fuel reforming, which may lead to NOx emissions.

15. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 15 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 Ambient condition variation tests – cold start test Cold start might be a problem with fuel cells in automotive applications and for startup of emergency generators in marine applications. Unlike in stationary applications, significant warm-up times are not acceptable to the customer. In addition, systems are not kept under controlled conditions, which may lead to system freezing and subsequent damage. It is therefore important to test the cold start performance to allow customer acceptance of fuel cell systems.

16. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 16 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 EMC Test With high current systems involved in propulsion systems, the radiated electromagnetic radiation could be significant. In addition, the system needs to be immune to radiation from the environment to ensure system and user safety. EMC performance of fuel cell systems should be measured on a prescribed driving cycle

17. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 17 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 Fuel consumption of fuel cell system on homologation cycle (H2 fuel) Driving range, on gaseous fuels is heavily dependent on the real efficiency of the system. All existing procedures for measuring fuel consumption of road vehicles make use of the carbon-balance method to determine the fuel consumption. This method is not applicable to a fuel cell system running on hydrogen fuel. Various solutions to these problems are being proposed

18. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 18 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 APU Voltage Regulation The goal of an APU is to deliver the required electrical power while maintaining a sufficient level of voltage regulation. Voltage regulation is critical for the proper functioning of the attached electrical loads. In this test module, a time varying pulsed load is applied to the APU, simulating the functioning of an automotive heating system. The test object considered is a hybrid APU, i.e. fuel cell system and energy storage together.

19. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 19 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 Power Quality – Transient Response Transient response of the fuel cell power generator depends on the power system architecture considering hybridisation by a buffer energy storage element (battery, supercapacitors…) or not. Hybridisation, depending on the system concept, could significantly reduce the power level (kW) delivered by the fuel cell generator under the working conditions and get a downsizing effect for the fuel cell generator. This test module simulates the transient load following capability of the fuel cell power generator, by: applying a transient load profile request and measuring the response of the actual delivered load.

20. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 20 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 Dielectric Strength (high voltage) At some point during the lifetime of a power generator, the generator will be subjected to high voltage peaks. For approval, the power generator has to be able to withstand temporary high voltages without destruction.

21. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 21 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 Crash Safety of a Fuel Cell System In the event of an accident, safety is critical for transport applications. A critical aspect of this is the safe containment of systems. This test method imposes a shock impulse on the fuel cell system (or alternatively a sustained equivalent load) to simulate the loading on the system that occurs during an accident. The system is deemed acceptable if the mountings retain the system in place.

22. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 22 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 Overload and short circuit In the event of an overload or short circuit condition, the fuel cell system should be capable of supplying this overload without damage to the system. This ensures system functionality in the event of a fault elsewhere in the electrical system. This test method presents tests for marine and aviation applications.

23. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 23 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 Identified missing test modules / 1 Important tests to be harmonised: Noise emissions Power performance capability Vibration testing Durability (thermo cycling; power throughput; power degradation) Ambient condition variation tests (temperature; humidity; pressure) These test modules were found to be important for all application areas (rail, marine, aviation, automotive), and could be harmonised among the various application areas to a large extent. Test methodologies could be largely the same for the different transport applications, while static test conditions and dynamic variations of input parameters (e.g. power cycles) could be made application specific.

24. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 24 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 General considerations on availability of tests and needs for harmonisation - Potential pre-normative research needs / 1 Only a few standards exist which are specific for fuel cell vehicles, fuel cell propulsion systems or fuel cell APUs APU-applications of fuel cells may be very important. At present little information is available on load profiles for various APU-applications; Application-oriented test procedures to be applied at the level of fuel cell systems are at present not available

25. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 25 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 Evaluation test procedures at the fuel cell system level could be developed as a “best practice”, but do not necessarily have to be formally standardised. Harmonisation at the European level, however, does seem useful, not only from an industry perspective, but also e.g. to enable evaluation and benchmarking of systems developed in various EU-funded projects; Type approval test procedures are within the domain of codes and standards. For LD road vehicles these will have to be defined at the vehicle level For HD road vehicles and most other transport applications procedures need to be defined at the “engine” level, i.e. at the level of fuel cell systems or fuel cell-driven power trains General considerations on availability of tests and needs for harmonisation - Potential pre-normative research needs / 2

26. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 26 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 The test cycles used for automotive type approval do not represent real- world driving. Different technologies may compare differently on the type approval test cycle compared to real-world test cycles. For fuel cell applications more insight is necessary on the impact of real-world use on efficiency and emissions; Type approval procedures for determining engine power can not be translated directly to fuel cells. General considerations on availability of tests and needs for harmonisation - Potential pre-normative research needs / 3

27. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 27 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 Further pre-normative activities verification of the presented test modules An important next step is verification of the presented test modules bringing the modules to a “best practices” level As usual with testing, many problems in testing procedures could only be identified during the actual execution of the tests. During this process, extra information could also become available which could help as to further specify the requirements and processes involved, bringing the modules to a “best practices” level. FCTESTNET test modules could assist the standardisatiuon procedures the FCTESTNET test modules could assist the standardisatiuon procedures Disseminating them at the standardisation bodies, could facilitate this process.

28. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 28 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 Other suggested RCS items In addition to all above mentioned items, other suggested RCS items may be: Modelling & validation of testing procedures (selection of test benchmarks to be compared against modelling) e.g.Hydrogen (accident scenarios), Fuel cell (Performance, of single cells, short stacks and systems)

29. EU Workshop – RCS on H 2 and FC Technologies for Vehicles Slide no. 29 EU-HarmonHy Workshop, Bruxelles, 26 September 2005 JRC-Institute for Energy Thank you for your attention! georgios.tsotridis@jrc.nl www.jrc.nl/fctestnet