1. NREL is a national laboratory of the U.S. Department of Energy Office of Energy Efficiency and Renewable Energy operated by the Alliance for Sustainable Energy, LLC High-Pressure H 2 : Validation Testing of SAE Performance Based System Level Standards NHA Hydrogen Conference Long Beach, CA Robert Burgess, NREL FCV Safety WG Member May 4, 2010

2. National Renewable Energy Laboratory Innovation for Our Energy Future Thanks to SAE FCV Safety Working Group Presentation materials provided by following working group members: Glenn Scheffler, Committee Chair (Consultant) Christine Sloane, (Consultant) Jake DeVaal (Ballard Power Systems Inc) Gery Kissel (General Motors) Michael Veenstra (Ford Motor Company) Tommy Chang and Naoki Kinoshita (Honda) Matt McClory (Toyota Motor Engr And Mfg North America) Hajime Fukumoto (Japan Automobile Research Institute) Marcel Halberstadt (MLH Consulting) Jesse Schneider (Consultant) Livio Gambone (Powertech Labs) Mark McDougal (Powertech Labs) Caroline Michaels (SAE)

3. National Renewable Energy Laboratory Innovation for Our Energy Future SAE FCV (Fuel Cell Vehicle) Activities  Objective  Address real-world system safety while providing flexibility for rapid advances in technology  Provide technical basis for regulatory requirements  Documents published:  SAE J1766 Post-crash electrical safety  SAE J2578 Fuel cell vehicle safety  SAE J2579 Vehicular hydrogen systems (TIR)  SAE J2600 GH 2 refueling connection devices  SAE J2601 Fueling protocols for GH 2  SAE J2615-2617 Performance testing protocols  SAE J2719 GH 2 quality guidelines  SAE J2760 Hydrogen system terminology (TIR)

4. National Renewable Energy Laboratory Innovation for Our Energy Future Fuel Cell Vehicles (FCVs) Integrating hydrogen, electrical, and fuel cell systems Compressed Hydrogen Containment System Fuel Cells Battery System Electric Power Control Electric Drive Motor

5. National Renewable Energy Laboratory Innovation for Our Energy Future CNG / Hydrogen Tank Standards Comparison CNGHydrogen Component LevelCSA NGV 2CSA HGV 2 Systems LevelFMVSS 303 & 304SAE TIR J2579 FMVSS – Federal Motor Vehicle Safety Standards TIR - Technical Information Report

6. National Renewable Energy Laboratory Innovation for Our Energy Future  Establishes clear expectations for the vehicle system based on foreseeable use  Addresses all parts, connections, and interactions within the system  Provides flexibility for future development  Does not dictate specific components or configurations  Avoids arbitrary flow down of requirements to components  Ensures direct connection to requirements for the targeted vehicle applications  Standard passenger  Heavy-duty commercial Why Focus on Systems-level Performance-based Requirements? on Systems-level

7. National Renewable Energy Laboratory Innovation for Our Energy Future Principle of “Design for Safety”  No single credible failure should cause unreasonable safety risk to persons or uncontrolled vehicle behavior  Isolation and containment of stored hydrogen is required to practice fault management on hydrogen and fuel cell vehicles.

8. National Renewable Energy Laboratory Innovation for Our Energy Future SAE J2579: Vehicular Hydrogen Systems Verification Tests For Foreseeable Use of Compressed Hydrogen Storage Systems  Expected Service Performance  Pneumatic cycle testing in hydrogen  Durability under Extended Usage and Extreme Conditions  Drop, flaw and chemical exposure  Hydraulic cycle testing  Performance under Service-terminating Conditions  Bonfire, penetration, burst

9. National Renewable Energy Laboratory Innovation for Our Energy Future Compressed Hydrogen Storage System Addressed in SAE J2579 Isolates stored hydrogen from -- the remainder of the fuel system the surrounding environment Container Vessel Container Isolation Valve Fill Check Valve Excess flow Receptacle with check Full System Isolation Low Pressure Regulator PRV High Pressure Regulator Downstream Hydrogen Piping for delivery to Fuel Cell System or Engine PRD Service Defuel Shufoff vent Compressed Hydrogen Storage System Includes all components and parts that form the primary pressure boundary for stored hydrogen

10. National Renewable Energy Laboratory Innovation for Our Energy Future Expected Service Performance Verification 25%cy -40 o C 25%cy +50 o C 125%NWP Leak/Permeation Final Burst Initial Burst <20% 30 sec 180%NWP Proof Test Static H2 Hold 500hr +85 o C Pressure  Time Pneumatic (H2) Pressure Cycles Static H2 Hold 500hr +85 o C 150%NWP Production Proof Test 25%cy -40 o C 25%cy +50 o C 125%NWP Pneumatic (H2) Pressure Cycles ----- 125% NWP

11. National Renewable Energy Laboratory Innovation for Our Energy Future Durability under extended usage & extreme conditions #Durability Cy 125%NWP 30 sec 180% NWP Proof Test 10cy T amb 150%NWP 150% NWP Production Test Pressure  Flaws & Chem** Drop * Time Final Burst Initial Burst <20% * Includes 1000 pressure cycles as part of the drop test procedure ** Includes a static pressure hold at 1.25 times NWP

12. National Renewable Energy Laboratory Innovation for Our Energy Future Service-terminating Conditions  Engulfing fire (bonfire) to demonstrate that the PRD(s) can protect the system from burst (note: PRD is thermally activated pressure relief device)  Penetration tests to demonstrate robustness of the wrap  Burst (and perhaps other) tests to show consistency within the verification batch and relevance to future production batches

13. National Renewable Energy Laboratory Innovation for Our Energy Future Burst Pressure Terminology

14. National Renewable Energy Laboratory Innovation for Our Energy Future

18. Burst Pressure Ratio Summary  Accelerated life testing at 125% NWP is equivalent to >25 years service life  Probability of vessel burst is lower than probability based on single strand data  Limit production burst pressure variation to +/- 10%  Improve production quality controls  Conducting 1000 hour static hold test at elevated temperature of 85°C will accelerate stress rupture, accounting for production variation

19. National Renewable Energy Laboratory Innovation for Our Energy Future DOE/NREL Sponsored Validation Testing  DOE/NREL sponsored validation testing of SAE J2579  Testing completed FY09  Validation testing as defined in sections 5.2.2.1 and 5.2.2.2  Extended service performance  Durability under extended usage and extreme conditions 70MPa Type 3 tank after residual strength burst test

20. National Renewable Energy Laboratory Innovation for Our Energy Future Validation Testing Conclusions  SAE J2579 test sequences are feasible.  State-of-the-art Type 3 and 4 tanks have passed both sequences.  Sequential nature of Expected Service Performance tests increases verification time from 8 weeks with CNG-type protocols to 12 weeks.  Durability performance test time is about 1 week.  Demonstrated that a Type 3 CNG tank that has failed in the field would also fail the test protocol

21. National Renewable Energy Laboratory Innovation for Our Energy Future Validation Testing – future work  Some components experienced seal leakage at extremely cold (below -40C) conditions, making further systems testing necessary. Component level testing for extreme temperature testing needs further validation  A type 4 tank experienced leakage due to high temperature cycling. This failure is thought to be attributed to liner failure. Photo of leak from 35MPa Type 4 system

22. National Renewable Energy Laboratory Innovation for Our Energy Future SAE J2579 Status/Plan STATUS  Test sequences in original issue of J2579 verified  Minor re-wordings identified to prevent misunderstandings  Local leak test added to identify point sources  Revision of SAE TIR J2579 published in January 2009  Reference-able document for system-level requirements  Appropriate guidance for system design and installation PLAN  Identify improvements  Develop options for reduced or decoupled testing  New localized fire requirements and methods  Revise and re-ballot as a Recommended Practice or a Standard  Include findings and results of activities conducted in 2007-2010  Provide a basis for national and global requirements

23. NREL is a national laboratory of the U.S. Department of Energy Office of Energy Efficiency and Renewable Energy operated by the Alliance for Sustainable Energy, LLC The White Sands Test Facility (WSTF) 2009 Composite Pressure Vessel and Structure Summit is an annual meeting where government agencies, industry, and academia are invited to discuss current fiber-reinforced composite (FRC) technology as it relates to composite pressure vessels and structures.  2009 Summit  Single strand data not applicable to COPV structure  Thirty years old data  Collaborative test program – data-data-data

24. National Renewable Energy Laboratory Innovation for Our Energy Future Summary  SAE is developing vehicle and systems-level, performance-based standards based on best available knowledge  Cooperating with other organizations to verify current standards and develop new capabilities  DOE-funded verification testing of methodologies  Japan Automobile Research Institute (JARI)  CSA America  NASA WSTF  Overall objective  FCVs to be used without restriction (garages, tunnels etc.)  Facilitate rapid advances by the industry  Provide technical basis for national & international requirements