2006 DOE Hydrogen Prog

Annual Merit Review

Hydrogen Codes and Stan

Jim Ohi

National Renewable Energy Laborato

May 19, 2006

Pr

This presentation does not contain any proprietary or confidential informatio

Presented at the 2006 DOE Hydrogen, Fuel Cells & Infrastructure Technologies Program 

held in Washington, D.C,.May 16-19, 2006.
Disclaimer and Government License

This work has been authored by Midwest Research Institute (MRI) under Contract No. DE-AC36Department of Energy (the “DOE”). The United States Government (the “Government”) retains athe work for publication, acknowledges that the Government retains a non-exclusive, paid-up, irrepublish or reproduce the published form of this work, or allow others to do so, for Government puNeither MRI, the DOE, the Government, nor any other agency thereof, nor any of their employeeor implied, or assumes any liability or responsibility for the accuracy, completeness, or usefulnesproduct, or process disclosed, or represents that its use would not infringe any privately owned ri

specific commercial product, process, or service by trade name, trademark, manufacturer, or othimply its endorsement, recommendation, or favoring by the Government or any agency thereof. authors and/or presenters expressed herein do not necessarily state or reflect those of MRI, the agency thereof. 
Overview

Timeline Bar

• Project start date: 10-1-05• Project end date: 9-30-06• Percent complete: 50

• Codes and Standards 

– Consensus nationstandards (J,A,B,D,– Limited DOE role standards and inadgovernment and indforums (F,G,H,I,K)– Current large foothydrogen fueling sta

Budget Part

• Total project funding

– DOE share: $1.26M– Contractor share: $22K

• Funding received in FY05: $2.0M• Funding for FY06: $1.28M

• National H2/Fuel Cells 

Coordinating Committe

• FreedomCAR-Fuel Par

Team

• North American H2 Fue
Objectives

• Strengthen and implement consensus national ag

and international codes and standards for hydrogen commercial, residential, and transportation applicat• Facilitate harmonization of requirements for hydrbased on consensus R&D• Enhance DOE’s role in development of ISO and standards and strengthen representation by governat international forums• Integrate codes and standards activities from R&D commercialization
Approach: Program Struct

NREL Focus Highlighted
Approach

• Strengthen and implement unified national agend

standards

– National templates adopted by consensus of SDO

• accelerate development of priority standards• designate and support lead SDO/CDOs• facilitate access to standards/model codes through 

– Coordinate national/international codes and stand

• National H2/Fuel Cells Codes and Standards Coord

• Coordinate and conduct R&D through Codes and 

Team R&D Roadmap

– Fuel-Vehicle Interface

• hydrogen fuel quality specifications• performance-based component testing and validatio

• Harmonize requirements in domestic and interna

– Work with and coordinate key participants, e.g., IC

SAE, IEC TC105-CSA, CGA-CSA/US TAGs 
Technical Accomplishments/P

• Unified national agenda for codes and standards

– Strengthened national consensus through Nationa

Coordinating Committee created in FY05 by DOEincludes all key SDOs, CDOs, state/federal agenc

– Negotiated contracts with all key SDO/CDO to dev

and model codes under significant budget constra

• R&D to develop defensible standards for hydrog

– Codes and Standards Tech Team R&D Roadmap 

• completed international guidelines for hydrogen fue• prepared R&D/test plan for hydrogen fuel quality• facilitate development of better risk-informed codes 

• Harmonize requirements in domestic and interna

– member of ISO/TC197 WG 12 to prepare hydroge

specification

– member U.S. Technical Advisory Group, ISO/TC1

Technologies

– work with CGA and CSA to coordinate ISO/TC197 – conduct semi-annual ISO-IEC “TAG-Team” meetin
Technical Accomplishments/Pr

Unified National Agenda for Codes a

• Integrated ANSI Hydrogen (and Fuel Cells) Codes 

(http://hcsp.ansi.org), DOE Hydrogen and Fuel Ce

Standards Matrix and Database (www.fuelcellstan

Hydrogen and Fuel Cell Safety Report (www.hydr

– provides comprehensive information regarding publ

standards documents, national and international counder development, and information for members oother stakeholders

• ASME completed Design Margin Guidelines for H

Hydrogen Tanks and Properties for Composite Ma

Service and will develop standards for high-pressufor stationary applications and use of non-steel mematerials for high-pressure hydrogen storage tank
Technical Accomplishments/Pr

Unified National Agenda for Codes a

• Compressed Gas Association (CGA), Administra

Technical Advisory Group (TAG) for ISO TC197 

Technologies) developed website to facilitate coproposed international standards, balloting on sp

• CSA-America developing performance-based re

gaseous hydrogen dispenser systems standards SAE

• Industry Panel on Hydrogen Codes (HIPOC) est

– neutral forum to develop and submit hydrogen-rela

ICC and NFPA and harmonize provisions in ICC astandards

• Transition SDO/CDO contracts to DOE-GO com
Technical Accomplishments/Pr

Unified National Agenda for Codes a
Technical Accomplishments/Pr

Unified National Agenda for Codes a
Technical Accomplishments/Pr

Unified National Agenda for Codes a
Technical Accomplishments/Pr

Codes and Standards R&D Roadmap 

Fueling Station-Vehicle Interface• Hydrogen Quality: Nozzle to Fuel Cell• Feedback Strategies• Dispenser Protocol and 

Testing (70 Mpa)

• Fueling Components • Station Grounding• Integrated Systems Design
Technical Accomplishments/Pr

Fuel Quality – ISO TS14687-2 Table of 

Table 1 — Directory of limiting characteristics 

Type I Type II Characteristics 

(assay) Grade D Grade D Laboratory Test Methods t

Hydrogen fuel index 

(minimum, %) a, b

99,99 99,99 

Para-hydrogen 

(minimum, %) 

NS 95,0 

Non-hydrogen constituents (maximum content) Dimensions in micromoles per mole unl

Total gases Error! 

Reference source not 

found.

100 100 

Water (H2O) 5 5 ASTM D6348, D5454, (D1946 & D5

Total hydrocarbons c

(C1 basis) 

2 2 EPA T012, T015, ASTM (D1946 & D5

K0114 

Oxygen (O2) 5 5 ASTM (D1946 & D5466) g, J

Helium (He), Nitrogen 

(N2), Argon (Ar) 

100 100 ASTM (D1946 & D5466) g, 

Carbon dioxide (CO2) 2 2 ASTM (D1946 & D5466)g, JIS K 

Carbon monoxide (CO) 0,2 0,2 EPA 25C, ASTM (D1946 & 

JIS K 0114, K 0123 

Total sulfur compounds d 0,004 f 0,004 f ASTM (D1946 & D5466) g, D550

Formaldehyde (HCHO) 0,01 0,01 EPA Method 11, NIOSH 2541, EPA T0

D5466) g, JIS K 0114, K 012

Formic acid (HCOOH) 0,2 f 0,2 f ASTM (D1946 & D5466) g, JIS K 

Ammonia (NH3) 0,1 f 0,1 f ASTM (D1946 & D5466) g, EPA T

Total halogenated 

Compounds 

0,05 0,05 EPA 200.7, JIS K10

Max Particulates Size e 10 μm 10 μm SCAQMD Method 301

Max Particulates 

Concentration e

1 μg/L @ NTP 1 μg/L @ NTP Gravimetric (EPA IO 3
Technical Accomplishments/Pr

Fuel Quality – R&D/Testing Approa

Collect, evaluate, and report assemblage of data and in

Recommend H

2 fuel quality specifications

Fuel cell performance 

characteristics as a 

function of H2

fuel contaminants

H2 fuel quality 

dependence on 

suppliers’ processing

technology

H2 storage media 

characteristics as 

a function of H2

fuel contaminants 

Fuel cell ve

characteris

H2 fue

An

instru

to m

fue

- Single contaminant/level- Contaminant/level 

combinations

- Test conditions

- operational- physical

- Long duration tests- Transient tests- Alternate catalysts

and materials

Modeling to support understanding of failure mechanisms, production/supply, material de

- Source of H2 fuel

production

- Method of cleanup- Alternative processes, 

methods for cleanup

- Technical, economic 

fuel-quality drivers

- Single contaminant/level- Contaminant/level

combinations

- Choices of materials- Long duration tests- Cyclic and transient

tests

- Operating conditions

- Deanaparaconkey - Idealte- Cotest
Technical Accomplishments/Pr

Fuel Quality – Effects of Non-hydrogen 

PEM Fuel Cells and Vehicle Syste

Species FC Stack BOP 

Inert gasses (Helium, Argon, Nitrogen)

H2 dilution effect, 

affects system efficiency

Will affect purging rate and blowers

Believecycle listorage 

Hydrocarbons Aromatics, acids, 

aldehydes, etc., degrade performance

Unknown May af

reactive media

Oxygen Tolerant to 

> 500 ppm

May form ice Believe

cycle listorage 

Carbon Monoxide

Reacts, degrades performance (reversible)

No effect Believe

cycle listorage 

Carbon Dioxide Tolerant at 100

ppm – limited CO back shifting

No effect Believe

cycle listorage 

Source: SAE
Technical Accomplishments/Pr

Fuel Quality – Specification Tradeo

Difficulty to Attain and Verify 

Low 

Low High

Impact on Fuel Cell

Carbon Mon

Carbon Dioxide

Ammonia

Aromatic & Aliphatic HCs

Oxyg

Source: Shell Hydrogen
Technical Accomplishments/Pr

Hydrogen Purification Drivers 

Halogenates Strong 0.05 ppmWater (H2O) Strong 5 ppm Dew Point Dew PointTotal Sulfur Strong 0.004 ppmAmmonia Strong 0.1 ppm Low ppm Low ppm

2 ppm 0.1 % 500 0.5% 25

(incl CH4)

Total HC’s |

Carbon Dioxide | 2 ppm 15-17% 85000 15 -18% 90(CO2)

2 ppm 0.5 – 2% 10000 0.5 – 3% 15

(incl THC)

Methane (CH4)

Carbon | 0.2 ppm 0.1 -1 % 50000 0.1-4% 200Monoxide (CO)

100 ppm 34-38% 3800 1000 ppm 1

(total inert)

Nitrogen (N2) |

100 ppm 500 ppm

5 500 ppm

(total inert)

Argon (Ar) |

Oxygen (O2) | 5 ppm 50 ppm 10 - 

Hydrogen (H2) Weak 99.99% 40-45% 75-80%

100 ppm 500 ppm

5 500 ppm

(total inert)

Helium (He) Zero

Purif

Ratio f

SMR

Mol %

Purification 

Ratio for ATR

ATR

Mol %

ISO TC 197 

WG 12 

(14687) 

Draft Spec

Adsorption 

Force

Species

Halogenates Strong 0.05 ppmWater (H2O) Strong 5 ppm Dew Point Dew PointTotal Sulfur Strong 0.004 ppmAmmonia Strong 0.1 ppm Low ppm Low ppm

2 ppm 0.1 % 500 0.5% 25

(incl CH4)

Total HC’s |

Carbon Dioxide | 2 ppm 15-17% 85000 15 -18% 90(CO2)

2 ppm 0.5 – 2% 10000 0.5 – 3% 15

(incl THC)

Methane (CH4)

Carbon | 0.2 ppm 0.1 -1 % 50000 0.1-4% 200Monoxide (CO)

100 ppm 34-38% 3800 1000 ppm 1

(total inert)

Nitrogen (N2) |

100 ppm 500 ppm

5 500 ppm

(total inert)

Argon (Ar) |

Oxygen (O2) | 5 ppm 50 ppm 10 - 

Hydrogen (H2) Weak 99.99% 40-45% 75-80%

100 ppm 500 ppm

5 500 ppm

(total inert)

Helium (He) Zero

Purif

Ratio f

SMR

Mol %

Purification 

Ratio for ATR

ATR

Mol %

ISO TC 197 

WG 12 

(14687) 

Draft Spec

Adsorption 

Force

Species

Source: Chevron
Technical Accomplishments/Pr

Fuel Quality – Critical Constituent

• To date, the North American team has identified thcritical constituents around which near-term R&D anfocused:

– CO– S compounds– He– CH

4 and inerts

– NH

3

– Particulate Matter (<10μ diameter)This list may change and other critical constituen

as R&D and testing proceed 
Technical Accomplishments/Pr

Fuel Quality – 5-year R&D/Testing P

Topic of InvestigationI. Consensus Testing Strategy

B. Develop R&D/test plan with WG12C. Coordinate activities, revise plan annuallyD. Derive optimal balance bet. fuel cell performance and fuel cost

II. Fuel Cell Tests ('standard' MEA)

 Determine mechanism

Alternate 

materials

Aging/const load Aging/variable load Aging w/regen

 Determine mechanisms 

E. Investigate performance/cost trade offs re: critical constituents

III. H2 Fuel Provider Integration

 A. Define H 2 fuel quality variations based on 

current cleanup procedures (relative to critical constituent limits)

 B. Define contaminant species/ concentration variations as a function of planned H 2 sources

 C. Investigate H 2 cleanup alternatives 

commensurate with fuel cell testsD. Conduct cost trade-offs re: critical constituents

IV. Analytical Protocol/Instrumentation

A. Evaluate adequacy of Table 1 info., set priorities based on IA

D. Assess cost trade-offs, esp. in-line 

measurement

V. OEM Engine/Vehicle Tests

VI. Advance Storage Materials

A. Track Development of Adv. Materials

2006 2007 2008 

Operations with limited contaminants and limits on conditions (load,SD/SU)

Determine variations to current practice

Investigate and incorporate required alternatives to SOP

 A. Conduct failure mechanism tests w/re concn. at const. load, RH, T & P with critical constituents (CO, H2S, etc.) B. Conduct long-term tests (const. physical conditions) and const. & variable loads with critical constituents (CO, H2S, etc.)

Identify regeneration 

alternatives

 C. Conduct tests with selected combinations of critical constituents (CO, H2S, etc.) and concentrations  C. Validate test methodology and requirements for critical constituents

Identify key species required to be monitored

Finalize species and concns to be monitored

 A. Fuel cell-OEMs/fuel providers select n critical species from Table 1 based on key technical/economic drivers D. Conduct "Simulated Drive Cycle" tests with H 2 + critical constituents as fuel 

 B. Modify ASTM standards to measure critical constituents as needed

Alternative materials 

cat. loading, etc.)

Operations with 'H2 Fconditions

Identify regeneration alternatives

Assemble and evaluate demo and fleet

vehicle operations with H 2 fuel q

Correlate small scale fuel cell 

tests with large scale A. H2 Fuel with Priority Constituents 
Technical Accomplishments/Pr

Safety Bibliographic Datab
Technical Accomplishments/Pr

Hydrogen Facilities Databa
Future Work

• Fuel Quality (FY06-07)

– coordinate R&D and testing in parallel with preparatio– focus R&D/testing on critical constituents identified a

drivers by consensus of fuel providers and fuel cell a

• cell testing• fuel cell system performance and durability trade-offs • fuel production, purification, delivery, options and cost t• sampling, analytic methodology, and instrumentation n

– develop consensus on critical analytical methods and 

verify recommended maximum levels of contaminant

– integrate findings, results with DOE H2 Quality Work

• Component Testing and Validation (FY06-07)

– harmonize performance-based test protocols and va

requirements in domestic and international hydrogen regulations

• streamline testing/validation through computer-aided e

Experiments, and other statistical techniques

• Sensor Testing and Validation (FY07)

– sensitivity, accuracy, selectivity, durability in laborato– develop criteria, test procedures relevant to integrate

approach

– measure performance dependence on temperature, 

outdoor air
Summary

• Strengthened consensus codes and standards agNational H2-FC C&S Coordinating Committee

- contracts with all key SDO/MCO to develop essenticodes under significant budget constraints

• Established and coordinated North American team 

prepare and submit draft ISO Technical Specificatioquality for PEMFC road vehicles 

- high priority for FreedomCAR- Fuel Partnership C&

• Created online hydrogen safety bibliographic data

- fulfills NAS recommendation

• Created online Geographic Information System (Gdatabase

- enables timely and informed response to hydrogen 

• Applying risk assessment techniques to develop bcodes and standards (with SNL)

- linked to IEA Annex 19 (Hydrogen Safety)
Supplemental Slides

The following slides are for the pu

reviewers only.
• “Accelerate efforts on hydrogen quality s

“focus on fuel quality, data collection, and u

– final draft of ISO specification submitted, ISO require

SAE– fuel quality incorporated in R&D Roadmap, designateCodes and Standards Tech Team– the North American team has developed 5-year and 

testing, data collection

Responses to Previous Year Reviewe
• “Move more budgets toward codes and s

and decrease general contributions made torganizations”- significant R&D budgets planned for integrated safety eng

testing and validation, sensor testing and validation eliminatereductions- R&D focus placed on fuel quality testing- less than 10% of budget going to an industry association (share) to support codes and standards coordination and provcommunication for C&S issues

Responses to Previous Year Reviewe
• “More attention to residential and comme

desirable”

- supporting revision of ICC model codes relevant 

commercial buildings- supporting revision of NFPA model codes and sstations- supporting R&D to establish scientific foundation hydrogen and fuel cell applications in telecommun

Responses to Previous Year Reviewe
Patents:

Two submitted for hydrogen safety sensor, prospective patents licePapers:• Overview Paper, Hydrogen Energy Cycle, MRS Symposium on H• Risk Assessment for Hydrogen Codes and Standards, 1st InternaHydrogen Safety; Pisa, Italy • DOE Hydrogen Codes and Standards Program, SAE Congress; Presentations: • Fuel quality R&D and Testing, ISO TC197 WG12; Palm Springs, • DOE Hydrogen Codes and Standards Program, SAE Congress; • Hydrogen Fuel Quality R&D Needs, Codes and Standards Tech • North American Consensus for Fuel Quality Requirements, ISO T

Japan• Fuel Quality R&D Plan, Fuel Cell Tech Team; Detroit, MI• Hydrogen Fuel Quality, National H2/FC C&S CC and US TAGs; D

Publications and Presentat
• Synchronization of Codes and Standards Developm

- better synchronization of codes and standards development establish a sound technical and scientific basis for requiremenand standards- scientific and technical basis requirements difficult to trace adevoting significant efforts to update requirements using the reby DOE and industry

• Performance-Based preferred over Design-Based, oStandards

- specifies tests component, subsystem, or system must pass materials made of or how designed- requirements for stationary applications will most probably rrequirements for vehicular applications should, to extent possbased

• Coordinating National and International Codes and Development 

- many major stakeholders involved in codes and standards oand clearly recognize need for close coordination and integratstandards development and international efforts to protect U.S- DOE will facilitate harmonization of requirements, including results from R&D efforts in formulating safety requirements, aeffort

Critical Assumptions
Technical Accomplishments/Pro

National Template for Vehicle Systems and R

Fuel Specs: SAE

ASTM, APIAnalytical Methods: ASTMWts/Measures:NIST, API, 

ASMEFueling: SAE, CSA

Sensors/Detectors: UL,

NFPA, SAE, CSAConnectors: SAE, CSA

Communications : SAE

UL, CSA, API, IEEE

CDTSCCPAEAF

Controlling Authority: State, Local Govt.

Zoning, Building Permits

Standards Development: Storage Tanks: ASME, CSA, CGA, NFPA, APIPiping: ASME, CSA, CGA, NFPA

Dispensers: CSA, UL, NFPA,

On-site H2 Production: CSA, UL, CGA, API

Codes for the Environment: ICC, NFPA

Controlling Authority: DOT/NHTSA (Crashworthiness)EPA (Emissions)Standards Development: General FC Vehicle Safety: SAEFuel Cell Vehicle Systems: SAEFuel System Components: CSAContainers: SAEReformers: SAEEmissions: SAERecycling SAEService/Repair: SAE

Vehicles F

Fueling, Service Parking F

Interface
Controlling Authority: 

OSHA, Emissions – EPA

Pipeline: DOT/PHMSA

State, Local Government 

Zoning, Building Permits

Standards Development: Electrolyzers: UL, CSA

Reformers: UL, CSA, API

Performance Test Procedures: ASME, CSA

Chemical Hydrides: UL,

CSA, NFPA

Controlling Authority: CPSC, DOT/PHMSA, OS

EPA (Methanol),

State, Local Govt. (Zoning, Building Permits

Standards Development: Handheld Systems: UL, CSA

Portable Systems: CSA, UL, CGA

Handheld Fuel Containers: UL, CSA, CGA

Portable Fuel Containers: CGA, CSA, ASME

H2 Fuel Specifications: CGA, SAE

Performance Test Procedures: NHA-GTI, ASME, 

SH

H

CF

F

FP

N

Installation Piping: ASME, CSA, CGA, NFPA, ICCStorage: ASME, CGA, CSA, API, NFPACompressors Safety Certification: CSA, ULCompressor Design, Performance & Safety: APISensors/Detectors: UL, CSA, NFPAFuel specifications: CGA, SAE, API, ASTMWeights/Measures: NIST, API, ASMEDispensers: NFPA, SAE, CSA, UL, APINon-vehicle Dispensing: CGACodes for Built Environment: ICC, NFPA, CGA, ASHRAE Interconnection: IEEE , UL, NFPA

Interface

Technical Accomplishments/Pr

National Template for Stationary and Po

Hydrogen Generator

Leads will change depending on type of environment.
Technical Accomplishments/Pr

Fuel Quality – North American Team 

• Bhaskar Balasubramanian, John Lemen, Chevron (C&STT, HPTT)• Bob Boyd, BOC Gases (ASTM, SAE)• Bill Collins, UTC Fuel Cells (ISO/TC197 WG12, USFCC, SAE)• Raul Dominguez, SCAQMD (ASTM D03)• Tony Estrada, PG&E (ASTM, SAE, ISO/TC197 WG12)• Karen Hall, NHA (ISO TC197 and WG12)• J.P. Hsu, Smart Chemistry (ASTM)• Tom Joseph, Air Products (CGA, NFPA, ISO TC197) • Jim Ohi, NREL (DOE HFCIT, C&STT)• Rick Rocheleau, University of Hawaii (ISO/TC197 WG12, DOD)• Leon Rubinstein, Patrick Kilough, Shell Hydrogen (HPTT, SAE, AST

• Jesse Schneider, Daimler-Chrysler (C&STT, SAE, ISO/TC197 WG1• Joe Schwartz, Praxair (CGA, NFPA)• Jim Simnick, BP (ASTM, HPTT)• Mike Steele, Fred Wagner, GM (C&STT, FCTT, SAE)• Tommy Rockward, Francisco Uribe, LANL (FCTT, USFCC/SCTRR)• Spenser Quong, Quong and Associates (ASTM, CaFCP)• Gerald Voecks, consultant to NREL (ISO/TC197 WG12)• Silvia Wessel, Ballard Power Systems (ISO/TC197 WG12, CaFCP, • Doug Wheeler, consultant to University of Hawaii (ISO/TC197 WG12• Robert Wichert, USFCC (ISO and TC197 WG12, IEC)