DELIVERABLE 3.5 REPORT GAP ANALYSIS OF FUTURE RCS NEEDS AT HIGH VOLUME PRODUCTION & USE Dissemination Level: PUBLIC HyLIFT-DEMO WP3, Task 3.3.1 Final Document Revision 1.0 (11 APR 2013) A. Pilenga, T. Malkow, G. Tsotridis (JRC) Acknowledgement This project is co-financed by European funds from the Fuel Cells and Joint Undertaking under FCH-JU-2009-1 Grant Agreement Number 256862. The project partners would like to thank the EU for establishing the fuel cells and hydrogen framework and or supporting this activity. The research leading to this review has received funding from the Seventh Framework Programme of the European Community for research, technological development and demonstration activities (FP7 2007-2013) under grant agreement number 256862.
R E P O R T Disclaimer The staff of HyLIFT-DEMO project partners prepared this report. The views and conclusions expressed in this document are those of the staff of the respective HyLIFT-DEMO partner(s). Neither the HyLIFT-DEMO partner(s), nor any of their employees, contractors or subcontractors, makes any warranty, expressed or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, product, or process enclosed, or represents that its use would not infringe on privately owned rights. Neither the Fuel Cells and Joint Undertaking (FCH JU) nor the European Union are liable for any use that may be made of the information contained herein.
CONTENTS CONTENTS...I LIST OF TABLES... II ACRONYMS AND ABBREVATIONS... III EXECUTIVE SUMMARY... V 1 INTRODUCTION AND MOTIVATION... 7 2 METHODOLOGY... 8 3 GAP ANALYSIS... 20 4 CONCLUSIONS AND RECOMMENDATIONS... 21 i
LIST OF TABLES Table 1: and fuel cell technologies RCS TEMPLATE... 8 Table 2: RCS citations for hydrogen related to forklifts...11 Table 3: Findings of existing RCS gaps for fuel cell (FC) powered forklifts...20 ii
ACRONYMS AND ABBREVATIONS AIAA American Institute of Aeronautics and Astronautics APU Auxiliary Power Units ASME American Society of Mechanical Engineers ASTM American Society for Testing and Materials ATEX Atmosphere explosible (explosive atmosphere) BS British Standard CD Committee Draft CGA Compressed Gas Association CGH Compressed Gaseous CHSV Compressed Surface Vehicle CSA Canadian Standards Association DoW Description of Work EC European Commission or European Communities (as the case may be) EIHP FP5 European Integrated Project EN European Norm EU European Union FC Fuel Cell FCH JU Fuel Cells and Joint Undertaking FCS Fuel Cell System FP Framework Programme for Research and Technological Development of the European Communities H 2 HarmonHy FP6 Harmonization of Regulations, Codes and Standards for a sustainable and Fuel Cell Technology SSA HGV Heavy Goods Vehicle HP Pressure HPRD HP Relief Device HRS Refuelling Station HSE UK Health and Safety Executive HyApproval FP6 Handbook for Approval of Refuelling Stations STREP ICC International Code Council IEC International Electrotechnical Commission IFC International Fire Code IFGC International Fuel Gas Code ISO International Organisation for Standardization KS Korean Standard LCA Life-Cycle Assessment LVD EU Low Voltage Directive 2006/95/EC MD EU Machinery Directive 2006/42/EC MH Materials Handling NASA National Aeronautics and Space Administration NFPA National Fire Protection Association OEM Original Equipment manufacturer OIML International Organization of Legal Metrology iii
PED PEM RCS RH SAE STREP SSA TAG TC TIR TR TS UK UL UPS VDI WG WP EU Pressure Equipment Directive 97/23/EC Proton Exchange Membrane Regulations, Codes and Standards Relative Humidity Society of Automotive Engineers Specific Targeted Research Project Specific Support Action Technical Advisory Group Technical Committee Technical Information Report Technical Report Technical Specification United Kingdom of Great Britain and Northern Ireland Underwriters Laboratory, Inc. Uninterrupted Power Supply Verein Deutscher Ingenieure Working Group Work Package iv
EXECUTIVE SUMMARY Background The Regulations, Codes and Standards (RCS) gap analysis was undertaken in the frame of the HyLIFT-DEMO project as part of the activities described in Work package 3 entitled "Safety Certification and RCS" (WP3) of the Description of Work (DoW), where it is required to identify future RCS needs in order to enable commercial high volume certification & use of hydrogen powered fuel cell material handling vehicles. This report This report assesses the data and evidence resulting from a survey performed with the aim to identify and analysis of RCS gaps on fuel cell (FC) powered forklifts and duplications within the standards industry as they relate to the deployment of and Fuel Cell power system for the lift truck market. Findings Existing RCS gaps as regards fuel cell powered forklifts are currently addressed by the standardization process in place at Working Group 6 "Fuel cell system for propulsion and auxiliary power units (APU)" of the Technical Committee 105 "Fuel Cell Technologies" of the International Electrotechnical Commission (IEC TC 105 WG6) for both performance and safety. Eventually, the standards will have performance requirements and type test methods available for system components and the entire FC power system. It is expected that compliance of FC forklifts with these standards presumes to meet the essential legal requirements of the applicable EU directives (i.e. Machinery 1-2006/42/EC, Low Voltage 2-2006/95/EC, Pressure Equipment 3-97/23/EC, ATEX Equipment 4-94/9/EC) and to facilitate the product certification process. Permitting guidelines 5 for the installation of hydrogen refuelling stations are also available including for indoor use. 6,7 1 See at http://ec.europa.eu/enterprise/sectors/mechanical/documents/legislation/machinery 2 See at http://ec.europa.eu/enterprise/sectors/electrical/lvd 3 See at http://ec.europa.eu/enterprise/sectors/pressure-and-gas/documents/ped 4 See at http://ec.europa.eu/enterprise/sectors/mechanical/atex/index_en.htm 5 D K Pritchard, M Royle & D Willough, Installation permitting guidance for hydrogen and fuel cell stationary applications: UK version, HSE Research Report RR715, 2009, Health and Safety Laboratory, Harpur Hill Buxton, Derbyshire, SK17 9JN, accessible at http://www.hse.gov.uk/research/rrhtm/rr715.htm 6 WP2 HyApproval - Handbook for Refuelling Station Approval, June 2008, accessible at http://www.hyapproval.org/publications.html v
Conclusions Overall conclusions are as follows: FC forklift performance test methods (IEC document 105/xxx/CD) and safety requirements and assessment methods (IEC document 105/407/CD) are currently under preparation at IEC TC 105 WG6, Existing permitting guidelines for the installation of hydrogen refuelling station should be used, and Operation and maintenance procedures should be defined by OEM (FC power system / forklift manufacturer). Suggestions and recommendations On the basis of the gap analysis, the following suggestions and recommendations emerge: To provide input on drafting of IEC 62282-4-101 & IEC 62282-4-102 Committee Drafts to IEC TC 105 WG6 and To demonstrate viability of these two Committee Drafts by validation trough testing. 7 NASA Safety Standard for and Systems: Guidelines for System Design, Materials Selection, Operations, Storage and Transportation, NSS 1740.16, Office of Safety and Mission Assurance Washington, DC 20546, February 1997, accessible at http://www.hq.nasa.gov/office/codeq/doctree/canceled/871916.pdf; cancelled in July 2005; Future acquisitions should cite AIAA 095-2004 Guide to Safety of and Systems, accessible at http://engineers.ihs.com/document/abstract/gfeihbaaaaaaaaaa vi
1 INTRODUCTION AND MOTIVATION This chapter provides background information on the project and explains the set-up of this report. Background The Regulations, Codes and Standards (RCS) gap analysis was undertaken in the frame of the HyLIFT-DEMO project 8 as part of the activities described in Work package 3 (WP3) of the Description of Work (DoW), where it is required to identify future RCS needs in order to enable commercial high volume certification & use of hydrogen powered fuel cell material handling vehicles. This report This report assesses the data and evidence resulting from a literature survey performed with the aim to identify and analyse RCS gaps on fuel cell (FC) powered forklifts and duplications within the standards industry as they relate to the deployment of and FC power system for the lift truck market. RCS gap analysis evaluations for H 2 technologies have been performed in the past years, starting with the HarmonHy project, 9 an European Union funded Specific Support Action (SSA) under the Sixth Framework Programme of the European Community for research, technological development and demonstration activities contributing to the creation of the European Research Area and to innovation, 2002 to 2006 (FP6) aiming to make an assessment of the activities on hydrogen and fuel cell RCS on a worldwide level. This report focuses on gaps in RCS that enables the production, commercialization and use of lift truck based on fuel cell technology. 8 See the project website at http://hylift-demo.eu 9 Harmonization of Regulations, Codes and Standards for a sustainable and Fuel Cell Technology, accessible at http://www.harmonhy.com 7
2 METHODOLOGY This chapter explains the pilot assessment methodology piloted in the project for the gap analysis. The gap analysis process was designed as a review of RCS already available or under preparation that are specifically related to the forklift application. There are many processes related to H 2 technology, an overview of all processes is given in Table 1. 10 Only the processes with assess tag have been investigated in this document. Table 1: and fuel cell technologies RCS TEMPLATE H 2 production Central production ISO 16110-1,2 Onsite reforming Onsite electrolysis Home production H 2 delivery production production Delivery HP composite Delivery HP conventional Delivery cryogenic NFPA 2 H 2 quality SAE, ASTM Pipelines ASME, CGA, IFC, IFGC, NFPA Tunnel delivery H 2 on-site bulk storage HP composite HP conventional Cryogenic H 2 fuel dispensing 10 Based on Preliminary gas Analysis H2 Technologies, Fuel Cell (FC) Technologies, Stationary & Portable FCs Automotive Applications, January 2005 (Revision 2) of the European Initiative Group (IG) RCS of the European and Fuel Cell Technology Platform, accessible at http://ec.europa.eu/research/energy/pdf/2_eu-ig-rcs_gap_analysis_en.pdf 8
Equipment nozzle 25-35 MPa Equipment nozzle 70 MPa Liquid dispenser Weight and measures (gas) Weight and measures (liquid) Fuel specification H 2 refuelling station site Piping, electrical Proximity to other fuels Safety integration Building codes Canopy On-site equipment H 2 stationary application Residential, remote site, power plants, UPS Forklift Ship Domestic residential cogen Recreative vehicle Telecom H 2 applications Domestic genset Catastrophe relief cogen, Portable Fair, market activities, events Military field duty Public recreation & 9
boating H 2 Automotive On-board storage system safety Whole vehicle safety Energy and environmental aspects Parking & garages Tunnels 10
Table 2: RCS citations for hydrogen related to forklifts RCS Scope Reference Organization Comment Standard for Fuel cell Power System For Installation in Industrial Electric Trucks The requirements cover fuel cell power systems currently noted as intended to be installed in type E, industrial trucks used in locations as defined in the Fire Safety Standard for Powered Industrial Trucks including Type Designations, Areas of Use, Conversions, Maintenance and Operations NFPA 505, and the National Electrical Code NFPA 70. The scope only covers those systems that incorporate a permanently mounted pressure vessel containing compressed hydrogen gas for designs that are fuel cell without the pressure vessel being removed from the industrial truck (on board fuelling). At this time, the standard is limited to systems with maximum pressures of 25 or 35 MPa. UL 2267 UL Even though the work of the High Pressure Task Group has been completed, there is a current proposal bulletin out for balloting that addresses tank replacement markings, changes to vibration and other testing and additional proposals for the pressure vessel section. Follow up revisions to the standard such as replacing the "Type E" industrial truck designation with the new industrial truck "Type CGH" (compressed gaseous hydrogen) designation in accordance with NFPA 505 are planned, to address developments in the industry and the codes that affect it. Fuel cell Safety requirements, IEC 62282-4-100 IEC The first draft will 11
RCS Scope Reference Organization Comment systems for forklift applications Fuel cell systems for forklift applications Fuel Cell Modules Basic Considerations for the Safety of Systems environmental aspects and test procedures Performance requirements and test procedures International standard providing minimum requirements for safety and performance of fuel cell modules in all applications Provides guidelines for the use of hydrogen in its gaseous and liquid forms. It identifies the basic safety concerns and risks, and describes the properties of hydrogen that are relevant to safety. Detailed safety requirements associated with specific hydrogen applications are Technical Committee No. 105 Fuel Cell Technologies Working Group 6 IEC 62282-4-200 Technical Committee No. 105 Fuel Cell Technologies Working Group #6 IEC 62282-2 (2012-03) Ed. 2 BS EN 62282-2:2012 CAN/CSA C22.2 No. 62282-2:07 KS C IEC 62282-2, IEC IEC combine relevant requirements from UL 2267, Fuel Cell Power Systems for Installation in Industrial Trucks, and IEC 62282-5. Portable Fuel Cell Appliances Safety. Target dates: Committee Draft June 2012 International March 2014. Standard China is in the process of adoption. ISO/TR 15916:2004 ISO A July 2010 proposal to revise this document was approved, and it will be conducted by a new working group, WG 16. 12
RCS Scope Reference Organization Comment treated in separate international Standards. Technologies Code NFPA 2 NFPA Type-approval of hydrogenpowered motor vehicle Type-approval of hydrogenpowered motor vehicles, and amending Directive 2007/46/EC Regulation (EC) No. 79/2009 EC Not applicable to offroad vehicle Pipeline Systems Joint European Industrial Gases Association/CGA international harmonized standard on metallic transmission and distribution systems carrying pure hydrogen and hydrogen mixtures CGA G-5.6 CGA WP2 Refueling Station WP3 Refueling Interface WP4 Vehicles WP5 Safety Development of a world-wide harmonized regulation for hydrogen fuelled road vehicles Development of procedures for periodic vehicle inspections. Development of a world-wide standard and periodic inspection procedure for refuelling infrastructure, subsystems and components. Under preparation European Integrated Project (EIHP) www.eihp.org FP6 Handbook for Approval of The aim of this project was to provide operators and local authorities with a handbook that Published September 30, 2008 www.hyapproval.org/publi EC 13
RCS Scope Reference Organization Comment Refueling Stations STREP Gaseous hydrogen Fuelling stations Gaseous Land Vehicle Refuelling Connection Devices Fuel Product Specification Quality Guideline For Fuel Cell Vehicles Compressed Vehicle Fueling Connection could be used to certify public hydrogen filling stations in Europe. Its intent was to provide guidance and uniformity specifies the characteristics of outdoor public and non-public fuelling stations that dispense gaseous hydrogen used as fuel onboard land vehicles of all types Applies to design, safety and operation verification of refuelling connection devices including nozzle, receptacle and protective cap. Part 2: Proton exchange membrane (PEM) fuel cell applications for road vehicles. SAE J2600 applies to the design and testing of Compressed Surface Vehicle (CHSV) fuelling connectors, nozzles, and receptacles. cations.hlml ISO/TS 20100:2008 ISO In Germany the VdTÜV Merkblatt Druckgas 514 is used for HRS ISO 17268:2012 ISO 14687-2 SAE J2719 SAE J 2600 ISO ISO SAE SAE 14
Devices RCS Scope Reference Organization Comment Fueling Protocols for Gaseous Powered Industrial Trucks (forklifts) TIR for Compressed Fuel Systems in Fuel Cell Powered Industrial Trucks Emissions and Fuel Consumption Working Group This document provides performance requirements for fuelling vehicles including a pressure test method to check for leaks, pressure limits for the vehicle fuelling system and target pressure compensation limits to manage the effects of vehicle tank temperature rise during the fuelling process The purpose of this document is to define design, construction, production, operational and maintenance requirements for hydrogen systems in industrial trucks and equipment. The standard defines requirements for compressed hydrogen storage systems and hydrogen processing systems as used by fuel cell power systems. Recommended Practice for Measuring the Exhaust Emissions, Energy Consumption and Range of Fuel Cell Powered Electric Vehicles using Compressed SAE TIR J2601/3 SAE Under preparation SAE J2919 SAE Under preparation SAE J2572 SAE General fuel Recommended practice for SAE J2578 SAE 15
RCS Scope Reference Organization Comment cell vehicle safety General fuel cell vehicle safety 70 Mpa Compressed SAE J2799 TIR SAE Surface Vehicle Refueling Connection Device and Optional Vehicle to Station Communicatio n Compressed Powered Industrial Trucks Onboard Fuel Storage and Handling Components This TAG shall develop standard(s) which provides performance based criteria and applicable details of construction for serially produced compressed hydrogen gas fuel storage and handling components constructed entirely of new unused parts and materials. This applies to powered industrial trucks powered by fuel cells or internal combustion engines. Such components include, but are not limited to (1) refillable containers intended only for the storage of compressed CSA America HPIT 1 Compressed Gas Vehicle Fuel Containers (CSA America HGV2) Pressure Relief Devices for Compressed Vehicle Fuel Containers (CSA America HPRD1) Fuel System Components for Compressed Powered Vehicles (CSA America CSA America Under preparation Anticipate publication as a CSA standard May 2013. 16
RCS Scope Reference Organization Comment hydrogen for powered industrial truck operation, (2) pressure relief devices produced for use on compressed hydrogen fuel containers, and (3) other fuel handling system components. This TAG is intended to develop coverage to supplement the provisions contained in the existing hydrogen component documents listed below and provides coverage specific to powered industrial truck applications. HGV 3.1) Compressed Station and Components for Fueling Industrial Trucks This TAG shall develop standard(s) which provides mechanical and electrical features and construction of newly manufactured systems that dispense hydrogen gas for powered industrial trucks, intended primarily to dispense fuel directly into the powered industrial truck fuel storage container. This TAG is intended to develop coverage to supplement the provisions contained in the existing hydrogen fuelling station and component documents listed CSA America HPIT 2 Compressed Dispensers (CSA America HGV 4.1) Hoses and Hose Assemblies (CSA America HGV 4.2) Fueling Parameter Verification (CSA America HGV 4.3) Breakaway Devices for Hoses (CSA America HGV 4.4) CSA Under preparation Anticipate publication as a CSA standard in February 2013 17
RCS Scope Reference Organization Comment below and provides coverage specific to powered industrial truck applications. Priority and Sequencing Equipment (CSA America HGV 4.5) Manually Operated Valves (CSA America HGV 4.6) Automatic Pressure Operated Valves (CSA America HGV 4.7) Gas Vehicle Fueling Station Compressor (CSA America HGV 4.8) Fueling Station Guideline (CSA America HGV 4.9) Fittings, (CSA America HGV 4.10) Compressed Gaseous Fuel Measuring Systems for Vehicles This Recommendation specifies the methodology and technical requirements applicable to compressed gaseous fuel measuring systems for vehicles, at type approval, initial verification and subsequent verifications. OIML R 139-1: Metrological and technical requirements OIML R 139-2: Metrological controls and performance tests IOLM A revision is underway to address, among other issues, new developments in hydrogen measurements. PED: Pressure Equipment directive Directive related to all pressurised systems 97/23/EC EC 18
RCS Scope Reference Organization Comment LVD: Low Voltage Directive MD: Machine Directive ATEX: Explosive Atmosphere Directives 2006/95/EC 2006/42/EC 94/9/EC & 99/92/EC EC EC EC 19
3 GAP ANALYSIS This chapter presents the outcome of the gap analysis in Table 3. Table 3: Findings of existing RCS gaps for fuel cell (FC) powered forklifts Gap Gap Resolution Documents Performance assessment of FC forklift Safety assessment of FC forklift Installation of H 2 refuelling stations for indoor use Validation of drafted standard UL 2267 for fuel economy, vibrations Validation of drafted standard Check on existent permitting guidelines for indoor use VDI Typenblatt 2198 IEC 62282-4-102: Fuel cell technologies Part 4-102: Fuel cell power systems for propulsion other than road vehicles and auxiliary power units Fuel cell power systems for industrial electrically driven forklift trucks Performance test methods IEC 62282-4-101: Fuel cell technologies Part 4-101: Fuel cell power systems for propulsion other than road vehicles and auxiliary power units Fuel cell power systems for industrial electrically driven forklift trucks Safety HyApproval handbook, see footnote 6 on page v of this report Additional evaluation on the effect of indoor release of hydrogen quality standard fuel Validation of proposed fuel quality level ISO /TC14687-2 ASTM standards, analysis SAE Technical Information Report (TIR) J2719 20
4 CONCLUSIONS AND RECOMMENDATIONS This chapter presents our main conclusions and recommendations It is concluded that: FC forklift performance test methods (IEC document 105/xxx/CD) 11 and safety requirements and assessment methods (IEC committee draft 105/407/CD) 12 are currently under preparation at IEC TC 105 WG6, Existing permitting guidelines for the installation of hydrogen refuelling station should be used, and Operation and maintenance procedures should be defined by OEM (FC power system / forklift manufacturer). Further, it is important to strength the cooperation among international RCS bodies and key stakeholders to improve standards development. Specifically, these actors should Provide input on drafting of IEC 62282-4-101 & IEC 62282-4-102 Committee Drafts to IEC TC 105 WG6 and Demonstrate viability of these two CDs by validation trough testing. 11 IEC 62282-4-102 Ed.1: : Fuel cell technologies - Part 4-102: Fuel cell power systems for industrial electric trucks Performance test methods 12 IEC 62282-4-101 Ed.1: Fuel cell technologies - Part 4-101: Fuel cell power systems for propulsion other than road vehicles and auxiliary power units - Fuel cell power systems for industrial electrically driven forklift trucks - Safety 21