as a fuel for mobility introduction of Regulations and homologation aspects linked to the

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1 BONG-HY (parallel application of Blends Of Natural Gas and HYdrogen in internal combustion engines and fuel cells) Regulations and homologation aspects linked to the introduction of of blends of hydrogen and natural gas as a fuel for mobility Ing.. Aldo Bassi e Ing.. Daniele Mizza Brescia,

2 SUMMARY 1. Performances and some technical aspects of CH4/H2 blends combustion in ICE- safety 2. Standards and Regulations International Organizations 3. Homologation procedure for a single prototype (Italy) 4. Safety aspects and reliability analysis - RAMS 5. Conclusions 2

3 3 MAIN CHARACTERISTICS OF FUELS: GASOLINE, LPG, METHANE, HYDROGEN GASOLINE LPG (propane butane) METANE HYDROGEN Lower Heat Power [MJ/Kg] 44, , Octane NumberRON C/H Ratio 0,54 0,38 0,4 0,25 0 Specific energy fuel-air mix [MJ/ m 3 ] Combustion speed [cm/sec] Lower flammable limit at 1 bar Upper flammable limit at 1 bar Vapour density at 1 bar [Kg/m 3 ] Fuel Vapour / Air density ratio Liquid density [Kg/ m 3 ] 3,65 3,48 3,18 2, ,0 % vol. 2,1 1,5 % vol. 5,0 % vol. 4,1 % vol. 7,6 % vol. 9,5 8,5 % vol. 15 % vol. 72,5 % vol. 4,75 1,83 2,42 0,67 0, ,9 1,5 2,0 0,56 0, [15 C] [15 C] 423 [-161 C] 70 [-252 C] Self Ignition temperature 320 C 465 C 540 C 560 C Boiling point ( C) 1 bar 125 C - 42 C - 1 C C C Vapour pressure REID (100 F) 0,25 0,45 bar (abs) 10,0 2,5 bar (abs) Propane - Buthane -

4 METHANE/HYDROGEN FEEDING SYSTEM OF INTERNAL COMBUSTION ENGINE (ICE) CYLINDER CYLINDER CYLINDER SAFETY MULTIVALVES AUTOMATIC VALVE PRESSURE REGULATOR H 2 SENSOR CYLINDER GAS TIGHT HOUSING CYLINDER GAS INJECTORS INTAKE MANIFOLD ENGINE SPARK PLUG EXHAUST MANIFOLD ELECTRONIC CONTROL UNIT ECU ENGINE SENSORS CATALIZER 4

5 SOME CHARACTERISTICS OF H 2 IN RESPECT TO SAFETY AND PERFORMANCES OF INTERNAL COMBUSTION ENGINE Wide ignition range (with air) generates unwanted mixture ignitions Low ignition energy generates unwanted mixture ignitions High self-ignition temperature means high octane number (> 130) less knock probability High flame speed means high combustion temperature i.e. high NOx emissions Low mixture H2/air density means low engine specific power Low H2 density make critical all the seals of engine High burn rates mean high heat losses 5

6 Hydrogen content [%] 6 Stored energy [%] Effect on the stored amount of energy on board of a natural gas vehicle, as a function of hydrogen content in the natural gas, with gas blend stored at 20 Mpa and 288K.

7 STANDARDS AND REGULATIONS Work in progress International Standards in ISO Regulation UN-ECE / UN-GTR Regulations & Procedures in Italy Homologation procedures as single prototype (ITALY) Risk analysis and reliablity - RAMS Homologation - Laboratory & road tests 7

8 WG1 Liquid fuel tanks ISO International Organization Standardization UN / ECE United Nations Economic Commission for Europe TC197 Hydrogen technologies TC22 Road Vehicles TC58 Gas cylinders Inland Transport Committee TC22/SC21 Electric road vehicles fuel cells. WG11 LPG Road Vehicles Containers WP.29 GRPE TC22/SC25 Road vehicles using LPG, CNG, H 2 Working Party on Pollution and Energy Ad Hoc Group H 2 and Fuel Cell GRPE WG1 Refuelling connector WG2 Design principles and installation of vehicle fuel system. WG3 Fuel system components. o ECE-Rxx : Liquid H 2 System & Components o ECE-Ryy : Compressed H 2 System & Components o ECE-Rzz: Fuel Cells Global Technical Regulations (GTR) WG5 Gas Filling connectors WG6 Gaseous fuel tanks WG8 Electrolysis processes WG9 Fuel processing tech. WG10 Metal Hydrides WG11 Service Stations WG12 Product Specifications European and International Gaseous Fuel Vehicles Standard Development 8

9 ISO TCs DEVELOPING H2 VEHICLES STANDARDS TC 197 Hydrogen Technologies - WG 1 Liquid hydrogen - Land vehicles fuel tanks - WG 5 Gaseous hydrogen - Land vehicle filling connectors - WG 6 Gaseous hydrogen and hydrogen blends - Land vehicle fuel tanks - WG 8 Hydrogen generators using water electrolysis process - WG 9 Hydrogen generators using fuel processing technologies - WG 10 Transportable gas storage devices - Hydrogen absorbed in reversible metal hydride - WG 11 Gaseous hydrogen - Service stations - WG 12 Hydrogen fuel - Product specification TC 22/SC25 Vehicles using gaseous fuels (CNG, LPG, H2) ITALIAN CHAIRMANSHIP - WG 1 Compressed natural gas refuelling connector - WG 2 Design principles and installation of vehicle fuel systems - WG 3 NGV fuel system components TC 22/SC21 Electrically propelled road vehicles - WG 1 Vehicle operation conditions, vehicle safety and energy storage installation - WG 2 Definitions and methods of measurement of vehicle performance and of energy consumption TC 58 Gas cylinders - WG 7 Compatibility between gases and materials 9

10 10 INTERNATIONAL STANDARD ISO CONCERNING HYDROGEN VEHICLES ISO/TR Basic considerations for the safety of hydrogen systems (TC 197) ISO/DIS Liquid hydrogen land vehicle fuel tanks (TC 197) ISO/DIS Filling connectors (250, 350, 500, 700 bar) (TC 197) ISO/DIS 13984:1999 Liquid H 2 Land vehicle fuelling system interface (TC197) ISO/WD xxxx.1 Road vehicles Compressed Gaseous Hydrogen (CGH2) and Hydrogen Blends fuel system components Part 1: General requirements and definitions (TC 22/SC25) ISO/WD xxxx.2 Road vehicles Compressed Gaseous Hydrogen (CGH2) and Hydrogen Blends fuel system components Part 2: Performance and general test methods (TC 22/SC25) ISO/WD xxxx.3 Road vehicles Compressed Gaseous Hydrogen (CGH2) and Hydrogen Blends fuel system components Part 3: Pressure regulator (TC 22/SC25) ISO/CD Gaseous H 2 e H 2 blends land vehicle fuel tank (TC )

11 11 INTERNATIONAL STANDARD ISO CONCERNING HYDROGEN VEHICLES cont ISO :2006 Fuel cell road vehicles -- Safety specifications Part 1: Vehicle functional safety (TC 22/SC21) ISO/FDIS Fuel cell road vehicles -- Safety specifications Part 2: Protection against hydrogen hazards for vehicles fuelled with compressed hydrogen (TC 22/SC21) ISO/DIS Fuel cell road vehicles -- Safety specifications Part 3: Protection of persons against electric shock (TC 22/SC21) ISO/CD Fuel Cell Hybrid Electric Road Vehicles Energy consumption measurement Part 1: Using compressed hydrogen (TC 22/SC21) ISO/WD Pure Fuel Road Vehicles Energy consumption measurement Part 1: Using compressed hydrogen (TC 22/SC21)

12 12 INTERNATIONAL ORGANIZATIONS FOR THE DEVELOPMENT OF HYDROGEN FUELLED VEHICLES TYPE APPROVAL REGULATIONS. GRPE WP29/AC3 GRSP SWG Environment emissions H 2 consumption PROJECT MANAGER GTR-HFCV Mr. Albus SWG Safety H 2 storage, vehicle crash electric safety SGE (Perujo del JRC-ISPRA) SGS (to be defined) H2 Industry mobile voice and stationary ISO H2 Voice EIHP2 Partnership EIHP is a partnership between the European Hydrogen Industry and the European Commission. This consortium was created to provide inputs for regulatory activities on a European and global level to facilitate harmonized Procedures for the approval of hydrogen fuelled road vehicles ISO TC22 SC21 Electric, Hybrid, FC Vehicles ISO TC197 Decision for cooperation between TC197 and TC22 was already taken on Hydrogen Technologies ISO TC22 SC25 LPG, CNG, H2 Road Vehicles

13 13 ECE-ONU REGULATIONS FOR HYDROGEN FUELLED VEHICLES TYPE APPROVAL ECE-ONU R xxx (GRPE/2003/14-7/03/03) Proposal: Specific components for motor vehicles using liquid hydrogen. Vehicles with regard to the installation of specific component ECE-ONU R yyy (GRPE/Informal doc) Proposal: Specific components for motor vehicles using compressed gaseous hydrogen. Vehicles with regard to the installation of specific component ECE-ONU R zzz (Draft regulation) Specific components of fuel cell for vehicles propulsion system Vehicles with regard to the installation of fuel cell ECE-ONU R 83 (draft amendment) Proposal: for introducing H 2 as propulsion fuel (exhaust emission measurements & certification tests) ECE-ONU R 85 (draft amendment) Proposal: for introducing H 2 as propulsion fuel (power output measurements & certification tests) ECE-ONU R 101 (draft amendment) Proposal: for introducing H 2 as propulsion fuel (fuel consumption and CO 2 emission measurements & certification tests) ECE-ONU R 100 (approved 12/02/97) Approval of battery electric vehicles with regard to specific requirements for construction and functional safety Nota: In the Regulation R 83, R 85, R 101 specific amendments are also proposed for introducing hybrid propulsion system certification test.

14 14 HYDROGEN VEHICLES REGULATIONS - OTHER ACTIVITIES - Round table for harmonization of Codes & Standard for CNG/H2 vehicles and infrastructures (ISO/GRPE) Geneve 2007 Mirror Committee H 2 Italy: CTI Comitato Termotecnico Italiano CUNA Commissione Tecnica di unificazione dell Autoveicolo CEI Comitato Elettrotecnico Italiano CUNA GL5 Gaseous fuel engines and their systems Italian organization for regulations in the automotive field Working Group on automotive engines fuelled with LPG,NG,H2,blends

15 15 HOMOLOGATION PROCEDURE FOR A VEHICLE FUELED WITH HYDROGEN, CNG/H2 BLENDS SINGLE PROTOTYPE (ITALY) Technical Report Risk Analysis (RAMS) required by Ministero Homologation Request (Ministero dei Trasporti) Nulla Osta Car Maker Lab and Road Tests Tests required by Car Maker Tests required by Ministero Type approval Certificate Registration ID. Plate

16 16 RAMS Reliability, Availability, Maintenance and Safety Functional Diagrams of the system and subsystems Data sheets components Mission profile Risk analysis FMECA / FTA Maintenance (Preventive & In-repair) Critical components pointing out (Minimal Cut Sets) Operability analysis

17 17 SINGLE VEHICLE TYPE APPROVAL TEST PROGRAM (ITALY) Breaking system tests only in the case of vehicle mass increase or modification ECE-ONU R.13 Electromagnetic compatibility (EMC) ECE-ONU R.10 Leakages measurements and hydrogen sensors test Short durability test on the vehicle on the road (i.e km) Inspection of the vehicle (Officier of Ministero dei Trasporti)

18 18 SAFETY ASPECTS OF H2 VEHICLES 1. On board H2 system: Leakages measurements and monitoring Safety valves (PRD, PRV) On board H 2 gas deposits prevention H 2 purges control Gas tight housing H 2 in air concentration sensors and alarm signals 2. In fire behaviour Safety valves (PRV, PRD, Burst disc) - Bonfire Test 3. Safety in crash (front, rear, lateral): Air tightness and ventilation test Gas leakages control after crash Cut-Off cylinder valves Components & cylinders fitting in crashtest simulation

19 19 CONCLUSIONS 1. Standards & Regulations for the homologation of CNG/H2 vehicles contain provisions of safety aspects in service. 2. ISO Committees & Subcommittees are working on ISO Standards as good engineering rules 3. GRPE/GRPS are working on GTR (Global Technical Regulation) world-wide application (2010) 4. EC will release a provisional Regulation for test fleet on the road in 2007 (?) 5. In Italy, the Type approval of single prototype for test fleet requires technical and test report including a risk analysis (RAMS) as safety performance demonstration.

UN-ECE / WP.29-AC3 HFCV - SGS. Federal Ministry of Transport, Building and Urban Affairs

UN-ECE / WP.29-AC3 HFCV - SGS. Federal Ministry of Transport, Building and Urban Affairs Federal Ministry of Transport, Building and Urban Affairs Christoph Albus Head of Division S 34 Vehicle Engineering / Environment GRPE / WP.29 Project Management of HFCV project Informal document No. GRSP-41-30