2010R0406 — EN — 01.07.2013 — 001.001

This document is meant purely as a documentation tool and the institutions do not assume any liability for its contents

►B COMMISSION REGULATION (EU) No 406/2010 of 26 April 2010 implementing Regulation (EC) No 79/2009 of the European Parliament and of the Council on type-approval of hydrogen-powered motor vehicles (Text with EEA relevance) (OJ L 122, 18.5.2010, p.1)

Amended by:









▼B

COMMISSION REGULATION (EU) No 406/2010

of 26 April 2010

implementing Regulation (EC) No 79/2009 of the European Parliament and of the Council on type-approval of hydrogen-powered motor vehicles

(Text with EEA relevance)







THE EUROPEAN COMMISSION, Having regard to the Treaty on the Functioning of the European Union, Having regard to Regulation (EC) No 79/2009 of the European Parliament and of the Council of 14 January 2009 on type-approval of hydrogen-powered motor vehicles, and amending Directive 2007/46/EC ( 1 ), and in particular Article 12 thereof, Whereas: (1) Regulation (EC) No 79/2009 is a separate Regulation for the purposes of the Community type-approval procedure provided for by Directive 2007/46/EC of the European Parliament and of the Council of 5 September 2007 establishing a framework for the approval of motor vehicles and their trailers, and of systems, components and separate technical units intended for such vehicles (Framework Directive) ( 2 ). (2) Regulation (EC) No 79/2009 lays down fundamental provisions on requirements for the type-approval of motor vehicles with regard to hydrogen propulsion, for the type-approval of hydrogen components and hydrogen systems and for the installation of such components and systems. (3) From entry into force of the present Regulation manufacturers should be able to apply for the EC whole-vehicle type-approval of hydrogen-powered vehicles on a voluntary basis. However, some of the separate Directives in the context of the Community type-approval procedure under Directive 2007/46/EC or some of their requirements should not apply to hydrogen-powered vehicles, since the technical characteristics of hydrogen-powered vehicles differ significantly from conventional ones, for which those type-approval Directives were essentially designed. Pending the amendment of those Directives to include specific provisions and test procedures on hydrogen-powered vehicles, it is necessary to set out transitional provisions in order to exempt hydrogen-powered vehicles from those Directive or some of their requirements. (4) Adopting harmonised rules on hydrogen receptacles, including receptacles designed to use liquid hydrogen, is necessary in order to ensure that hydrogen vehicles can be refuelled throughout the Community in a safe and reliable manner. (5) The measures provided for in this Regulation are in accordance with the opinion of the Technical Committee — Motor Vehicles, Whereas: HAS ADOPTED THIS REGULATION:







Article 1

Definitions

For the purposes of this Regulation, the following definitions shall apply:

(1) ‘Hydrogen sensor’ means a sensor used to detect hydrogen in air;

(2) ‘Class 0 component’ means high-pressure hydrogen components including fuel lines and fittings containing hydrogen at a nominal working pressure greater than 3,0 MPa;

(3) ‘Class 1 component’ means medium-pressure hydrogen components including fuel lines and fittings containing hydrogen at a nominal working pressure greater than 0,45 MPa and up to and including 3,0 MPa;

(4) ‘Class 2 component’ means low-pressure hydrogen components including fuel lines and fittings containing hydrogen at a nominal working pressure up to and including 0,45 MPa;

(5) ‘Fully wrap’ means over-wrap with the filaments wound around the liner both in the circumferential and longitudinal directions of the container;

(6) ‘Hoop wrap’ means over-wrap with the filaments wound in a substantially circumferential pattern over the cylindrical portion of the liner, so that the filaments do not carry any significant load in the longitudinal direction of the container;

(7) ‘Nm3’ or ‘Ncm3’ means a volume of dry gas that occupies a volume of 1 m3 or 1 cm3 at a temperature of 273,15 K (0 °C) and an absolute pressure of 101,325 kPa (1 atm);

(8) ‘Service life’ means the life in years during which the containers may safely be used in accordance with the service conditions;

(9) ‘Type of hydrogen system’ means a group of hydrogen systems which do not differ either as regards their trade name or mark of their manufacturer or as regards the hydrogen components included therein;

(10) ‘Vehicle type with regard to hydrogen propulsion’ means a group of vehicles which do not differ as regards the state of the hydrogen used or the main characteristics of its hydrogen system(s);

(11) ‘Type of hydrogen component’ means a group of hydrogen components which do not differ in any of the following aspects: (a) trade name or mark of their manufacturer; (b) classification; (c) main function;

(12) ‘Electronic control system’ means a combination of units, designed to cooperate in the production of the stated vehicle control function by electronic data processing;

(13) ‘Complex electronic vehicle control systems’ mean electronic control systems which are subject to a hierarchy of control in which one electronically controlled function may be over-ridden by a higher-level system/function and become part of the complex system;

(14) ‘Container’ means any system used for the storage of cryogenic hydrogen or compressed gaseous hydrogen, excluding any other hydrogen components which may be attached to or fitted inside the container;

(15) ‘Container Assembly’ means two or more containers with integral interconnecting fuel lines, protectively encased inside a housing shell or protective frame;

(16) ‘Duty Cycle’ means one start up and shut down cycle of the hydrogen conversion system(s);

(17) ‘Filling cycle’ means a pressure increase of more than 25 per cent of the working pressure of the container due to an external source of hydrogen;

(18) ‘Pressure regulator’ means a device used to control the delivery pressure of gaseous fuel to the hydrogen conversion system;

(19) ‘First pressure regulator’ means the pressure regulator having the container pressure as its inlet pressure;

(20) ‘Non-return valve’ means a valve that allows hydrogen to flow in only one direction;

(21) ‘Pressure’ means gauge pressure measured in MPa against atmospheric pressure, unless otherwise stated;

(22) ‘Fitting’ means a connector used in a piping, tubing or hose system;

(23) ‘Flexible fuel line’ means flexible tubing or a hose through which hydrogen flows;

(24) ‘Heat exchanger’ means a device for heating the hydrogen;

(25) ‘Hydrogen filter’ means a filter used to separate oil, water and dirt from hydrogen;

(26) ‘Automatic valve’ means a valve that is not operated manually, but by an actuator, with the exception of non-return valves as defined in point 20;

(27) ‘Pressure relief device’ means a non-reclosing device that, when activated under specified conditions, is used to release fluid from a pressurised hydrogen system;

(28) ‘Pressure relief valve’ means a reclosing pressure activated device that, when activated under specified conditions, is used to release fluid from a pressurised hydrogen system;

(29) ‘Refuelling connection’ or ‘receptacle’ means a device used to fill the container at the filling station;

(30) ‘Removable storage system’ means a removable system within a vehicle that houses and protects one or more container(s) or a container assembly;

(31) ‘Removable storage system connector’ means the hydrogen connection device between a removable storage system and the section of the hydrogen system permanently installed in the vehicle;

(32) ‘Auto-frettage’ means a pressure application procedure used in manufacturing composite containers with metal liners, which strains the liner past its yield point sufficiently to cause permanent plastic deformation, which results in the liner having compressive stresses and the fibres having tensile stresses at zero internal pressure;

(33) ‘Liner’ means a part of a container that is used as a gas tight inner shell, on which reinforcing fibres are filament wound to reach the necessary strength;

(34) ‘Ambient temperature’ means a temperature range of 20 °C ± 10 °C;

(35) ‘Units’ mean the smallest divisions of system components for the purposes of Annex VI, as these combinations of components are treated as single entities for purposes of identification, analysis or replacement;

(36) ‘Ground clearance of the vehicle’ means the distance between the ground plane and the underside of the vehicle;

(37) ‘Safety device’ means a device that ensures safe operation within the normal operating range or the permissible fault range of the system;

(38) ‘Hydrogen conversion system’ means any system designed for the conversion of hydrogen into electrical, mechanical or thermal energy and includes, for example, the propulsion system(s) or auxiliary power unit(s);

(39) ‘Impermissible fault range’ of a process variable means the range within which an unwanted event is to be expected;

(40) ‘Leak test gas’ means hydrogen, helium or an inert gas mixture containing a demonstrated detectable amount of helium or hydrogen gas;

(41) ‘Normal operating range’ of a process variable means the range planned for its values;

(42) ‘Outer pressure’ means the pressure acting on the convex side of the inner tank or outer jacket;

(43) ‘Outer jacket’ means the part of the container that encases the inner tank(s) and its insulation system;

(44) ‘Rigid fuel line’ means tubing that has not been designed to flex in normal operation and through which hydrogen flows;

(45) ‘Boil off management system’ means a system that renders boil off gas harmless in normal conditions;

(46) ‘Safety instrumented systems’ mean process control systems that prevent an impermissible fault range from being reached by an automatic intervention in the process;

(47) ‘Batch’ means a quantity of successively produced finished containers having the same nominal dimensions, design, specified materials of construction, process of manufacture, equipment for manufacture and, where appropriate, conditions of time, temperature and atmosphere during heat treatment;

(48) ‘Equipment of the container’ means all devices that are fixed directly to the inner tank or outer jacket of the container;

(49) ‘Finished container’ means a container that is typical of normal production, complete with external coating including integral insulation specified by the manufacturer, but free from non-integral insulation or protection;

(50) ‘Burst pressure’ means the pressure at which the container ruptures;

(51) ‘Permissible fault range’ of a process variable means the range between the normal operating range and the impermissible fault range;

(52) ‘Boil off system’ means a system that in normal conditions vents the boil-off before the pressure relief device of the container(s) opens;

(53) ‘Manual valve’ means a manually operated valve;

(54) ‘Safety concept’ means measures designed to ensure safe operation even in the event of a failure or random faults;

(55) ‘Usage monitoring and control system’ means a system that counts the filling cycles and prevents further use of the vehicle when a predetermined number of filling cycles is exceeded;

(56) ‘Fuel supply line’ means the line that supplies hydrogen to the hydrogen conversion system(s);

(57) ‘Composite container’ means a container constructed of more than one material;

(58) ‘Over-wrap’ means resin impregnated continuous filaments used as reinforcement around a liner;

(59) ‘Auto-frettage pressure’ means the pressure within the over-wrapped container at which the required distribution of stresses between the liner and the over-wrap is established;

(60) ‘Boundary of functional operation’ means the boundaries of the external physical limits within which a system is able to maintain control;

(61) ‘Range of control’ means the range over which the system is likely to exercise control with regard to an output variable;

(62) ‘Transmission links’ mean the means used for interconnecting distributed units for the purpose of conveying signals, operating data or an energy supply;

(63) ‘Higher-level systems/functions’ mean controls that employ additional processing and/or sensing provisions to modify vehicle behaviour by commanding variations in the normal function(s) of the vehicle control system.

Article 2

Administrative provisions for EC type-approval of a vehicle with regard to hydrogen propulsion

1. The manufacturer or his representative shall submit to the type-approval authority the application for EC type-approval of a vehicle with regard to hydrogen propulsion.

2. The application shall be drawn in accordance with the model of the information document set out in Part 1 of Annex I.

The manufacturer shall provide the information set out in Part 3 of Annex I for periodic requalification by inspection during the service life of the vehicle.

3. If the relevant requirements set out in Part 1 of Annex III or Part 1 of Annex IV, Annex V and Annex VI are met, the approval authority shall grant an EC type-approval and issue a type-approval number in accordance with the numbering system set out in Annex VII to Directive 2007/46/EC.

A Member State may not assign the same number to another vehicle type.

4. For the purposes of paragraph 3, the type-approval authority shall deliver an EC type-approval certificate established in accordance with the model set out in Part 2 of Annex I.

Article 3

Administrative provisions for EC component type-approval of hydrogen components and systems

1. The manufacturer or his representative shall submit to the type-approval authority the application for EC component type-approval for a type of hydrogen component or hydrogen system.

The application shall be drawn up in accordance with the model of the information document set out in Part 1 of Annex II.

2. If the relevant requirements set out in Annex III or Annex IV are met, the approval authority shall grant an EC component type-approval and issue a type-approval number in accordance with the numbering system set out in Annex VII to Directive 2007/46/EC.

A Member State may not assign the same number to another type of hydrogen component or hydrogen system.

3. For the purposes of paragraph 2, the type-approval authority shall deliver an EC type-approval certificate established in accordance with the model set out in Part 2 of Annex II.

Article 4

For the purpose of the EC whole-vehicle type-approval of hydrogen-powered vehicles in accordance to Articles 6 and 9 of Directive 2007/46/EC, the following shall not apply:

(1) Council Directive 80/1268/EEC ( 3 );

(2) Council Directive 80/1269/EEC ( 4 ), as regards hydrogen-powered vehicles propelled by internal combustion engine;

(3) Annex I to Council Directive 70/221/EEC ( 5 );

(4) Section 3.3.5 of Annex II and Section 4.3.2 of Appendix 1 to Annex II to Directive 96/27/EC of the European Parliament and of the Council ( 6 );

(5) Section 3.2.6 of Annex II and Section 1.4.2.2 of Appendix 1 to Annex II to Directive 96/79/EC of the European Parliament and of the Council ( 7 ).

Article 5

EC component type-approval mark

Every hydrogen component or hydrogen system conforming to a type in respect of which EC component type-approval has been granted pursuant to this Regulation shall bear an EC component type-approval mark as set out in Part 3 of Annex II.

Article 6

Entry into force

This Regulation shall enter into force on the 20th day following its publication in the Official Journal of the European Union.

This Regulation shall be binding in its entirety and directly applicable in all Member States.









LIST OF ANNEXES







ANNEX I Administrative documents for EC type-approval of vehicles with regard to hydrogen propulsion Part 1 Information document Part 2 EC type-approval certificate Part 3 Information to be provided for inspection ANNEX II Administrative documents for EC component type-approval of hydrogen components and systems Part 1 Information document Part 2 EC type-approval certificate Part 3 EC component type-approval mark ANNEX III Requirements for hydrogen components and systems designed to use liquid hydrogen and their installation on hydrogen powered vehicles Part 1 Requirements for the installation of hydrogen components and systems designed to use liquid hydrogen on hydrogen powered vehicles Part 2 Requirements for hydrogen containers designed to use liquid hydrogen Part 3 Requirements for hydrogen components other than containers designed to use liquid hydrogen ANNEX IV Requirements for hydrogen components and systems designed to use compressed (gaseous) hydrogen and their installation on hydrogen powered vehicles Part 1 Requirements for the installation of hydrogen components and systems designed to use compressed (gaseous) hydrogen on hydrogen powered vehicles Part 2 Requirements for hydrogen containers designed to use compressed (gaseous) hydrogen Part 3 Requirements for hydrogen components other than containers designed to use compressed (gaseous) hydrogen ANNEX V Vehicle identification requirements ANNEX VI Safety requirements of complex electronic vehicle control systems ANNEX VII Standards referenced by this Regulation









ANNEX I

Administrative Documents for EC type-approval of vehicles with regard to hydrogen propulsion

PART 1

MODEL

INFORMATION DOCUMENT No …

relating to EC type-approval of a vehicle with regard to hydrogen propulsion

The following information shall be supplied in triplicate and include a list of contents. Any drawings shall be supplied in appropriate scale and in sufficient detail on size A4 or on a folder of A4 format. Photographs, if any, shall show sufficient detail.

If the systems or components have electronic controls, information concerning their performance shall be supplied.







0. GENERAL 0.1. Make (trade name of manufacturer): … 0.2. Type: … 0.2.1 Commercial name(s) (if available): … 0.3. Means of identification of type, if marked on the vehicle (1) (): … 0.3.1. Location of that marking: … 0.4. Category of vehicle (): … 0.5. Name and address of manufacturer: … 0.8. Name(s) and address(es) of assembly plant(s): … 0.9. Name and address of the manufacturer's representative (if any): … 1. GENERAL CONSTRUCTION CHARACTERISTICS OF THE VEHICLE 1.1 Photographs and/or drawings of a representative vehicle: … 1.3.3. Powered axles (number, position, interconnection): … 1.4. Chassis (if any) (overall drawing): … 3. POWER PLANT 3.9. Hydrogen propulsion 3.9.1. Hydrogen system designed to use liquid hydrogen / Hydrogen system designed to use compressed (gaseous) hydrogen (1) 3.9.1.1. Description and drawing of the hydrogen system: … 3.9.1.2. Name and address of the manufacturer(s) of the hydrogen system used for the propulsion of the vehicle: … 3.9.1.3. Manufacturer's system code(s) (as marked on the system, or other means of identification): … 3.9.1.4. Automatic shut-off valve(s): yes/no (1) 3.9.1.4.1. Make(s): … 3.9.1.4.2. Type(s): … 3.9.1.4.3. Maximum Allowable Working Pressure (MAWP) (1) (2) MPa 3.9.1.4.4. Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2): … MPa 3.9.1.4.5. Operating temperature (1): … 3.9.1.4.6. Number of filling cycles or duty cycles as appropriate (1): … 3.9.1.4.7. Approval number: … 3.9.1.4.8. Material: … 3.9.1.4.9. Operating principles: … 3.9.1.4.10. Description and drawing: … 3.9.1.5. Check valve(s) or non-return valve(s): yes/no (1) 3.9.1.5.1. Make(s): … 3.9.1.5.2. Type(s): … 3.9.1.5.3. Maximum Allowable Working Pressure (MAWP) (1) (2) … MPa 3.9.1.5.4. Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2): … MPa 3.9.1.5.5. Operating temperature (1): … 3.9.1.5.6. Number of filling cycles or duty cycles as appropriate (1): … 3.9.1.5.7. Approval number: … 3.9.1.5.8. Material: … 3.9.1.5.9. Operating principles: … 3.9.1.5.10. Description and drawing: … 3.9.1.6. Container(s) and container assembly: yes/no (1) 3.9.1.6.1. Make(s): … 3.9.1.6.2. Type(s): … 3.9.1.6.3. Maximum Allowable Working Pressure (MAWP) (1) (2) … MPa 3.9.1.6.4. Nominal working pressure (1) (2): … MPa 3.9.1.6.5. Number of filling cycles (1): … 3.9.1.6.6. Operating temperature (1): … 3.9.1.6.7. Capacity: … litres (water) 3.9.1.6.8. Approval number: … 3.9.1.6.9. Material: … 3.9.1.6.10. Operating principles: … 3.9.1.6.11. Description and drawing: … 3.9.1.7. Fittings: yes/no (1) 3.9.1.7.1. Make(s): … 3.9.1.7.2. Type(s): … 3.9.1.7.3. Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (2): … MPa 3.9.1.7.4. Number of filling cycles or duty cycles as appropriate: … 3.9.1.7.5. Approval number: … 3.9.1.7.6. Material: … 3.9.1.7.7. Operating principles: … 3.9.1.7.8. Description and drawing: … 3.9.1.8. Flexible fuel line(s): yes/no (1) 3.9.1.8.1. Make(s): … 3.9.1.8.2. Type(s): … 3.9.1.8.3. Maximum Allowable Working Pressure (MAWP) (1) (2) … MPa 3.9.1.8.4. Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2): … MPa 3.9.1.8.5. Operating temperature (1): … 3.9.1.8.6. Number of filling cycles or duty cycles as appropriate (1): … 3.9.1.8.7. Approval number: … 3.9.1.8.8. Material: … 3.9.1.8.9. Operating principles: … 3.9.1.8.10. Description and drawing: … 3.9.1.9. Heat exchanger(s): yes/no (1) 3.9.1.9.1. Make(s): … 3.9.1.9.2. Type(s): … 3.9.1.9.3. Maximum Allowable Working Pressure (MAWP) (1) (2) … MPa 3.9.1.9.4. Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2): … MPa 3.9.1.9.5. Operating temperature (1): … 3.9.1.9.6. Number of filling cycles or duty cycles as appropriate (1): … 3.9.1.9.7. Approval number: … 3.9.1.9.8. Material: … 3.9.1.9.9. Operating principles: … 3.9.1.9.10. Description and drawing: … 3.9.1.10. Hydrogen filter(s): yes/no (1) … 3.9.1.10.1. Make(s): … 3.9.1.10.2. Type(s): … 3.9.1.10.3. Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2): … MPa 3.9.1.10.4. Number of filling cycles or duty cycles as appropriate (1): … 3.9.1.10.5. Approval number: … 3.9.1.10.6. Material: … 3.9.1.10.7. Operating principles: … 3.9.1.10.8. Description and drawing: … 3.9.1.11. Hydrogen leakage detection sensors: … 3.9.1.11.1. Make(s): … 3.9.1.11.2. Type(s): … 3.9.1.11.3. Maximum Allowable Working Pressure (MAWP) (1) (2) … MPa 3.9.1.11.4. Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2): … MPa 3.9.1.11.5. Operating temperature (1): … 3.9.1.11.6. Number of filling cycles or duty cycles as appropriate (1): … 3.9.1.11.7. Set values: … 3.9.1.11.8. Approval number: … 3.9.1.11.9. Material: … 3.9.1.11.10. Operating principles: … 3.9.1.11.11. Description and drawing: … 3.9.1.12. Manual or automatic valve(s): yes/no (1) … 3.9.1.12.1. Make(s): … 3.9.1.12.2. Type(s): … 3.9.1.12.3. Maximum Allowable Working Pressure (MAWP) (1) (2) … MPa 3.9.1.12.4. Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2): … MPa 3.9.1.12.5. Operating temperature (1): … 3.9.1.12.6. Number of filling cycles or duty cycles as appropriate (1): … 3.9.1.12.7. Approval number: … 3.9.1.12.8. Material: … 3.9.1.12.9. Operating principles: … 3.9.1.12.10. Description and drawing: … 3.9.1.13. Pressure and/or temperature and/or hydrogen and/or flow sensor(s) (1): yes/no (1) … 3.9.1.13.1. Make(s): … 3.9.1.13.2. Type(s): … 3.9.1.13.3. Maximum Allowable Working Pressure (MAWP) (1) (2) … MPa 3.9.1.13.4. Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2): … MPa 3.9.1.13.5. Operating temperature (1): … 3.9.1.13.6. Number of filling cycles or duty cycles as appropriate (1): … 3.9.1.13.7. Set values: … 3.9.1.13.8. Approval number: … 3.9.1.13.9. Material: … 3.9.1.13.10. Operating principles: … 3.9.1.13.11. Description and drawing: … 3.9.1.14. Pressure regulator(s): yes/no (1) … 3.9.1.14.1. Make(s): … 3.9.1.14.2. Type(s): … 3.9.1.14.3. Number of main adjustment points: … 3.9.1.14.4. Description of principle of adjustment through main adjustment points: … 3.9.1.14.5. Number of idle adjustment points: … 3.9.1.14.6. Description of principles of adjustment through idle adjustment points: … 3.9.1.14.7. Other adjustment possibilities: if so and which (description and drawings): … 3.9.1.14.8. Maximum Allowable Working Pressure (MAWP) (1) (2) … MPa 3.9.1.14.9. Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2): … MPa 3.9.1.14.10. Operating temperature (1): … 3.9.1.14.11. Number of filling cycles or duty cycles as appropriate (1): … 3.9.1.14.12. Input and output pressure: … 3.9.1.14.13. Approval number: … 3.9.1.14.14. Material: … 3.9.1.14.15. Operating principles: … 3.9.1.14.16. Description and drawing: … 3.9.1.15. Pressure relief device: yes/no (1) … 3.9.1.15.1. Make(s): … 3.9.1.15.2. Type(s): … 3.9.1.15.3. Maximum Allowable Working Pressure (MAWP) (1) (2) … MPa 3.9.1.15.4. Operating temperature (1): … 3.9.1.15.5. Set pressure (1): … 3.9.1.15.6. Set temperature (1): … 3.9.1.15.7. Blow off capacity (1): … 3.9.1.15.8. Normal maximum operating temperature: (1) (2) … °C 3.9.1.15.9. Nominal working pressure(s) (1) (2): … MPa 3.9.1.15.10. Number of filling cycles (Class 0 components only) (1): … 3.9.1.15.11. Approval number: … 3.9.1.15.12. Material: … 3.9.1.15.13. Operating principles: … 3.9.1.15.14. Description and drawing: … 3.9.1.16. Pressure relief valve: yes/no (1) … 3.9.1.16.1. Make(s): … 3.9.1.16.2. Type(s): … 3.9.1.16.3. Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2): … MPa 3.9.1.16.4. Set pressure (1): … 3.9.1.16.5. Number of filling cycles or duty cycles as appropriate (1): … 3.9.1.16.6. Approval number: … 3.9.1.16.7. Material: … 3.9.1.16.8. Operating principles: … 3.9.1.16.9. Description and drawing: … 3.9.1.17. Refuelling connection or receptacle: yes/no (1) … 3.9.1.17.1. Make(s): … 3.9.1.17.2. Type(s): … 3.9.1.17.3. Maximum Allowable Working Pressure (MAWP) (1) (2) … MPa 3.9.1.17.4. Operating temperature (1): … 3.9.1.17.5. Nominal working pressure(s) (1) (2): … MPa 3.9.1.17.6. Number of filling cycles (Class 0 components only) (1): … 3.9.1.17.7. Approval number: … 3.9.1.17.8. Material: … 3.9.1.17.9. Operating principles: … 3.9.1.17.10. Description and drawing: … 3.9.1.18. Removable storage system connector: yes/no (1) … 3.9.1.18.1. Make(s): … 3.9.1.18.2. Type(s): … 3.9.1.18.3. Nominal working pressure(s) and maximum allowable working pressure(s) (2): … MPa 3.9.1.18.4. Number of duty cycles: … 3.9.1.18.5. Approval number: … 3.9.1.18.6. Material: … 3.9.1.18.7. Operating principles: … 3.9.1.18.8. Description and drawing: … 3.9.2. Further documentation … 3.9.2.1. Process diagram (flow chart) of the hydrogen system … 3.9.2.2. System layout including electrical connections and other external system (inputs and/or outputs etc.) … 3.9.2.3. Key to symbols used in documentation … 3.9.2.4. Adjustment data of pressure relief devices and pressure regulators … 3.9.2.5. Layout of cooling/heating system(s) including Nominal or Maximum Allowable Working Pressure (NAWP or MAWP) and operating temperatures … 3.9.2.6. Drawings showing requirements for installation and operation. (1) Delete where not applicable (there are cases where nothing needs to be deleted when more than one entry is applicable). (2) Specify the tolerance (3) If the means of identification of type contains characters not relevant to describe the vehicle, component or separate technical unit types covered by this information document, such characters shall be represented in the documentation by the symbol ‘?’ (e.g. ABC??123??). (4) Classified according to the definitions set out in Part A of Annex II to Directive 2007/46/EC.









Appendix to information document

Statement of Service for Hydrogen Containers







Manufacturer identification Manufacturer name: Manufacturer address: Container identification Container identification: Nominal working pressure: MPa Type: Diameter (1): mm Length (1): mm Internal volume: litres Empty weight: kg Container threads: Container service life Maximum service life: Maximum number of fillingcycles: years cycles Container fire protection system Pressure relief device manufacturer: Pressure relief device identification: Pressure relief device drawing number(s): Container support method Support method: neck/cylinder mounting (2) Support drawing number(s): Container protective coatings Purpose of protection: Protective coating drawing number(s): Container design description Container drawing numbers: Container drawings shall show at least the following information: — Reference to this Regulation and the container type — Principal geometrical dimensions including tolerances — Container materials — Container mass and internal volume including tolerances — Details of the exterior protective coating — Container fire protection system Container corrosion inhibitor Container corrosion inhibitor used: yes/no (2) Corrosion inhibitor manufacturer: Corrosion inhibitor identification: Additional information 1. Manufacturing data including tolerances where appropriate: — Tube extrusion, cold deformation, tube drawing, end forming, welding, heat treatment and cleaning processes for the metal manufacturing of all containers designed to use liquid hydrogen and type 1, 2 and 3 containers designed to use compressed (gaseous) hydrogen — Reference to the manufacturing procedure — Acceptance criteria for non-destructive examination (NDE) — Composite manufacturing processes and auto-frettage according to section 3.7.2. of Part 2 to Annex IV for the manufacturing of type 2, 3 and 4 containers designed to use compressed (gaseous) hydrogen — Final manufacturing inspection of surface finish, thread details and principal dimensions 2. A table summarising the results of stress analysis Container statement of service The manufacturer hereby states that the container design is suitable for use during the specified service life in the service conditions set out in section 2.7 of Annex IV to Regulation (EU) No 406/2010. Manufacturer: Name, position and signature: Place, date: (1) May be replaced by other dimensions defining the shape of the container. (2) Delete as appropriate.

PART 2

MODEL

Maximum format: A4 (210 × 297 mm)

EC TYPE-APPROVAL CERTIFICATE

Stamp of type-approval authority

Communication concerning:







— EC type-approval (1) of a type of a vehicle with regard to hydrogen propulsion ( 1 ) — extension of EC type-approval (1) — refusal of EC type-approval (1) — withdrawal of EC type-approval (1) (1) Delete where not applicable

with regard to Regulation (EC) No 79/2009, as implemented by Regulation (EU) No 406/2010.

EC type-approval number:

Reason for extension:

SECTION I

0.1. Make (trade name of manufacturer):

0.2. Type: 0.2.1. Commercial name(s) (if available):

0.3. Means of identification of type, if marked on the vehicle ( 8 ): 0.3.1. Location of that marking:

0.4. Category of vehicle ( 9 ):

0.5. Name and address of manufacturer:

0.8. Name(s) and address(es) of assembly plant(s):

0.9. Name and address of the manufacturer's representative (if any):

SECTION II

1. Additional information (where applicable): see Addendum

2. Technical service responsible for carrying out the tests:

3. Date of test report:

4. Number of test report:

5. Remarks (if any): see Addendum

6. Place:

7. Date:

8. Signature: Attachments : Information package. Test report.



Addendum to EC type-approval certificate No … relating to EC type-approval of a vehicle with regard to hydrogen propulsion 1. Additional information 1.1. Vehicle equipped with hydrogen system designed to use liquid hydrogen / hydrogen system designed to use compressed (gaseous) hydrogen ( 10 ) 2. Type-approval number of each hydrogen component or system installed on the vehicle type to comply with this Regulation 2.1. Hydrogen system(s): 2.2. Automatic shut-off valve(s): 2.3. Check valve(s) or non-return valve(s): 2.4. Container(s) and container assembly: 2.5. Fittings: 2.6. Flexible fuel line(s): 2.7. Heat exchanger(s): 2.8. Hydrogen filter(s): 2.9. Hydrogen leakage detection sensors: 2.10. Manual or automatic valve(s): 2.11. Pressure and/or temperature and/or hydrogen and/or flow sensor(s) (10) : 2.12. Pressure regulator(s): 2.13. Pressure relief device: 2.14. Pressure relief valve: 2.15. Refuelling connection or receptacle: 2.16. Removable storage system connector: 3. Remarks:

PART 3

Information to be provided for inspection

1. Manufacturers shall provide: (a) recommendations for inspection or testing of the hydrogen system during its service life; (b) information on the need for periodic inspection and the necessary frequency in the owners’ manual of the vehicle or by means of a label close to the location of the statutory plate according to Council Directive 76/114/EEC ( 11 ).

2. Manufacturers shall make the information specified in section 1 available to approval authorities and the competent authorities in the Member States responsible for the periodic inspection of vehicles in the form of manuals or by means of electronic media (e.g. CD-ROM, on-line services).









ANNEX II

Administrative documents for EC component type-approval of hydrogen components and systems

PART 1

MODEL

INFORMATION DOCUMENT No

relating to EC component type-approval of a hydrogen component or system

The following information shall be supplied in triplicate and include a list of contents. Any drawings shall be supplied in appropriate scale and in sufficient detail on size A4 or on a folder of A4 format. Photographs, if any, shall show sufficient detail.

If the systems or components have electronic controls, information concerning their performance shall be supplied.







0. GENERAL 0.1. Make (trade name of manufacturer): … 0.2. Type: … 0.2.1 Commercial name(s) (if available): … 0.2.2 Reference or part number of the component (1): … 0.2.3 Reference(s) or part number(s) of the component(s) in the system (1): 0.2.4 Reference or part number of the system (1): … 0.5. Name(s) and address(es) of manufacturer: … 0.7. Location and method of affixing of the EC type-approval mark(s): 0.8. Name(s) and address(es) of assembly plant(s): … 0.9. Name and address of the manufacturer's representative (if any): … 3.9. Hydrogen propulsion (1): … 3.9.1. Hydrogen system designed to use liquid hydrogen / Hydrogen system designed to use compressed (gaseous) hydrogen / Hydrogen component designed to use liquid hydrogen / Hydrogen component designed to use compressed (gaseous) hydrogen (1): … 3.9.1.1. Description and drawing of the hydrogen system (1): … 3.9.1.2. Name and address of the manufacturer(s) of the hydrogen system (1): … 3.9.1.3. Manufacturer's system code(s) (as marked on the system, or other means of identification) (1): … 3.9.1.4. Automatic shut-off valve(s): yes/no (1) … 3.9.1.4.1. Make(s): … 3.9.1.4.2. Type(s): … 3.9.1.4.3. Maximum Allowable Working Pressure (MAWP) (1) (2) … MPa 3.9.1.4.4. Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2): … MPa 3.9.1.4.5. Operating temperature (1): … 3.9.1.4.6. Number of filling cycles or duty cycles as appropriate (1): … 3.9.1.4.7. Approval number: … 3.9.1.4.8. Material: … 3.9.1.4.9. Operating principles: … 3.9.1.4.10. Description and drawing: … 3.9.1.5. Check valve(s) or non-return valve(s): yes/no (1) … 3.9.1.5.1. Make(s): … 3.9.1.5.2. Type(s): … 3.9.1.5.3. Maximum Allowable Working Pressure (MAWP) (1) (2) … MPa 3.9.1.5.4. Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2): … MPa 3.9.1.5.5. Operating temperature (1): … 3.9.1.5.6. Number of filling cycles or duty cycles as appropriate (1): … 3.9.1.5.7. Approval number: … 3.9.1.5.8. Material: … 3.9.1.5.9. Operating principles: … 3.9.1.5.10. Description and drawing: … 3.9.1.6. Container(s) and container assembly: yes/no (1) … 3.9.1.6.1. Make(s): … 3.9.1.6.2. Type(s): … 3.9.1.6.3. Maximum Allowable Working Pressure (MAWP) (1) (2) … MPa 3.9.1.6.4. Nominal working pressure (1) (2): … MPa 3.9.1.6.5. Number of filling cycles (1): … 3.9.1.6.6. Operating temperature (1): … 3.9.1.6.7. Capacity: … litres (water) 3.9.1.6.8. Approval number: … 3.9.1.6.9. Material: … 3.9.1.6.10. Operating principles: … 3.9.1.6.11. Description and drawing: … 3.9.1.7. Fittings: yes/no (1) … 3.9.1.7.1. Make(s): … 3.9.1.7.2. Type(s): … 3.9.1.7.3. Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (2): … MPa 3.9.1.7.4. Number of filling cycles or duty cycles as appropriate: … 3.9.1.7.5. Approval number: … 3.9.1.7.6. Material: … 3.9.1.7.7. Operating principles: … 3.9.1.7.8. Description and drawing: … 3.9.1.8. Flexible fuel line(s): yes/no (1) … 3.9.1.8.1. Make(s): … 3.9.1.8.2. Type(s): … 3.9.1.8.3. Maximum Allowable Working Pressure (MAWP) (1) (2) … MPa 3.9.1.8.4. Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2): … MPa 3.9.1.8.5. Operating temperature (1): … 3.9.1.8.6. Number of filling cycles or duty cycles as appropriate (1): … 3.9.1.8.7. Approval number: … 3.9.1.8.8. Material: … 3.9.1.8.9. Operating principles: … 3.9.1.8.10. Description and drawing: … 3.9.1.9. Heat exchanger(s): yes/no (1) … 3.9.1.9.1. Make(s): … 3.9.1.9.2. Type(s): … 3.9.1.9.3. Maximum Allowable Working Pressure (MAWP (1) (2) … MPa 3.9.1.9.4. Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2): … MPa 3.9.1.9.5. Operating temperature (1): … 3.9.1.9.6. Number of filling cycles or duty cycles as appropriate (1): … 3.9.1.9.7. Approval number: … 3.9.1.9.8. Material: … 3.9.1.9.9. Operating principles: … 3.9.1.9.10. Description and drawing: … 3.9.1.10. Hydrogen filter(s): yes/no (1) … 3.9.1.10.1. Make(s): … 3.9.1.10.2. Type(s): … 3.9.1.10.3. Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2): MPa 3.9.1.10.4. Number of filling cycles or duty cycles as appropriate (1): … 3.9.1.10.5. Approval number: … 3.9.1.10.6. Material: … 3.9.1.10.7. Operating principles: … 3.9.1.10.8. Description and drawing: … 3.9.1.11. Hydrogen leakage detection sensors: … 3.9.1.11.1. Make(s): … 3.9.1.11.2. Type(s): … 3.9.1.11.3. Maximum Allowable Working Pressure (MAWP) (1) (2) … MPa 3.9.1.11.4. Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2): … MPa 3.9.1.11.5. Operating temperature (1): … 3.9.1.11.6. Number of filling cycles or duty cycles as appropriate (1): … 3.9.1.11.7. Set values: … 3.9.1.11.8. Approval number: … 3.9.1.11.9. Material: … 3.9.1.11.10. Operating principles: … 3.9.1.11.11. Description and drawing: … 3.9.1.12. Manual or automatic valve(s): yes/no (1) … 3.9.1.12.1. Make(s): … 3.9.1.12.2. Type(s): … 3.9.1.12.3. Maximum Allowable Working Pressure (MAWP) (1) (2) … MPa 3.9.1.12.4. Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2): … MPa 3.9.1.12.5. Operating temperature (1): … 3.9.1.12.6. Number of filling cycles or duty cycles as appropriate (1): … 3.9.1.12.7. Approval number: … 3.9.1.12.8. Material: … 3.9.1.12.9. Operating principles: … 3.9.1.12.10. Description and drawing: … 3.9.1.13. Pressure and/or temperature and/or hydrogen and/or flow sensor(s) (1): yes/no (1) … 3.9.1.13.1. Make(s): … 3.9.1.13.2. Type(s): … 3.9.1.13.3. Maximum Allowable Working Pressure (MAWP) (1) (2) … MPa 3.9.1.13.4. Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2): … MPa 3.9.1.13.5. Operating temperature (1): … 3.9.1.13.6. Number of filling cycles or duty cycles as appropriate (1): … 3.9.1.13.7. Set values: … 3.9.1.13.8. Approval number: … 3.9.1.13.9. Material: … 3.9.1.13.10. Operating principles: … 3.9.1.13.11. Description and drawing: … 3.9.1.14. Pressure regulator(s): yes/no (1) … 3.9.1.14.1. Make(s): … 3.9.1.14.2. Type(s): … 3.9.1.14.3. Number of main adjustment points: … 3.9.1.14.4. Description of principle of adjustment through main adjustment points: … 3.9.1.14.5. Number of idle adjustment points: … 3.9.1.14.6. Description of principles of adjustment through idle adjustment points: … 3.9.1.14.7. Other adjustment possibilities: if so and which (description and drawings): … 3.9.1.14.8. Maximum Allowable Working Pressure (MAWP) (1) (2) … MPa 3.9.1.14.9. Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2): … MPa 3.9.1.14.10. Operating temperature (1): … 3.9.1.14.11. Number of filling cycles or duty cycles as appropriate (1): … 3.9.1.14.12. Input and output pressure: … 3.9.1.14.13. Approval number: … 3.9.1.14.14. Material: … 3.9.1.14.15. Operating principles: … 3.9.1.14.16. Description and drawing: … 3.9.1.15. Pressure relief device: yes/no (1) … 3.9.1.15.1. Make(s): … 3.9.1.15.2. Type(s): … 3.9.1.15.3. Maximum Allowable Working Pressure (MAWP) (1) (2) … MPa 3.9.1.15.4. Operating temperature (1): … 3.9.1.15.5. Set pressure (1): … 3.9.1.15.6. Set temperature (1): … 3.9.1.15.7. Blow off capacity (1): … 3.9.1.15.8. Operating temperature (1): 3.9.1.15.9. Normal maximum operating temperature (1) (2): … °C 3.9.1.15.10. Nominal working pressure(s) (1) (2): … MPa 3.9.1.15.11. Number of filling cycles (Class 0 components only) (1): … 3.9.1.15.12. Approval number: … 3.9.1.15.13. Material: … 3.9.1.15.14. Operating principles: … 3.9.1.15.15. Description and drawing: … 3.9.1.16. Pressure relief valve: yes/no (1) … 3.9.1.16.1. Make(s): … 3.9.1.16.2. Type(s): … 3.9.1.16.3. Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2): … MPa 3.9.1.16.4. Set pressure (1): … 3.9.1.16.5. Number of filling cycles or duty cycles as appropriate (1): … 3.9.1.16.6. Approval number: … 3.9.1.16.7. Material: … 3.9.1.16.8. Operating principles: … 3.9.1.16.9. Description and drawing: … 3.9.1.17. Refuelling connection or receptacle: yes/no (1) … 3.9.1.17.1. Make(s): … 3.9.1.17.2. Type(s): … 3.9.1.17.3. Maximum Allowable Working Pressure (MAWP) (1) (2) … MPa 3.9.1.17.4. Operating temperature (1): … 3.9.1.17.5. Nominal working pressure(s) (1) (2): … MPa 3.9.1.17.6. Number of filling cycles (Class 0 components only) (1): … 3.9.1.17.7. Approval number: … 3.9.1.17.8. Material: … 3.9.1.17.9. Operating principles: … 3.9.1.17.10. Description and drawing: … 3.9.1.18. Removable storage system connector: yes/no (1) … 3.9.1.18.1. Make(s): … 3.9.1.18.2. Type(s): … 3.9.1.18.3. Nominal working pressure(s) and maximum allowable working pressure(s) (2): … MPa 3.9.1.18.4. Number of duty cycles: … 3.9.1.18.5. Approval number: … 3.9.1.18.6. Material: … 3.9.1.18.7. Operating principles: … 3.9.1.18.8. Description and drawing: … 3.9.2. Further documentation … 3.9.2.1. Process diagram (flow chart) of the hydrogen system … 3.9.2.2. System layout including electrical connections and other external system (inputs and/or outputs etc.) … 3.9.2.3. Key to symbols used in documentation … 3.9.2.4. Adjustment data of pressure relief devices and pressure regulators … 3.9.2.5. Layout of cooling/heating system(s) including Nominal or Maximum Allowable Working Pressure (NAWP or MAWP) and operating temperatures … 3.9.2.6. Drawings showing requirements for installation and operation … (1) Delete where not applicable (there are cases where nothing needs to be deleted when more than one entry is applicable). (2) Specify the tolerance.









Appendix to information document

Statement of Service for Hydrogen Containers







Manufacturer identification Manufacturer name: Manufacturer address: Container identification Container identification: Nominal working pressure: MPa Type: Diameter (1): mm Length (1): mm Internal volume: litres Empty weight: kg Container threads: Container service life Maximum service life: years Maximum number of filling cycles: cycles Container fire protection system Pressure relief device manufacturer: Pressure relief device identification: Pressure relief device drawing number(s): Container support method Support method: neck/cylinder mounting (2) Support drawing number(s): Container protective coatings Purpose of protection: Protective coating drawing number(s): Container design description Container drawing numbers: Container drawings shall show at least the following information: — Reference to this Regulation and the container type — Principal geometrical dimensions including tolerances — Container materials — Container mass and internal volume including tolerances — Details of the exterior protective coating — Container fire protection system Container corrosion inhibitor Container corrosion inhibitor used: yes/no (2) Corrosion inhibitor manufacturer: Corrosion inhibitor identification: Additional information 1. Manufacturing data including tolerances where appropriate: — Tube extrusion, cold deformation, tube drawing, end forming, welding, heat treatment and cleaning processes for the metal manufacturing of all containers designed to use liquid hydrogen and type 1, 2 and 3 containers designed to use compressed (gaseous) hydrogen — Reference to the manufacturing procedure — Acceptance criteria for non-destructive examination (NDE) — Composite manufacturing processes and auto-frettage according to section 3.7.2. of Part 2 to Annex IV for the manufacturing of type 2, 3 and 4 containers designed to use compressed (gaseous) hydrogen — Final manufacturing inspection of surface finish, thread details and principal dimensions 2. A table summarising the results of stress analysis Container statement of service The manufacturer hereby states that the container design is suitable for use during the specified service life in the service conditions set out in section 2.7 of Annex IV to Regulation (EU) No 406/2010. Manufacturer: Name, position and signature: Place, date: (1) May be replaced by other dimensions defining the shape of the container. (2) Delete as appropriate.

Specifications of containers designed to use compressed (gaseous) hydrogen







Material specification Applicable to Material Steel Aluminium alloy Plastic liner Fibre Resin Coating Details Material manufacturer Type of material Material identification Heat treatment definition Chemical composition Cold- or cryoforming procedure Welding procedure definition







Specifications for material tests Applicable to Material Steel Aluminium alloy Plastic liner Fibre Resin Coating Specified material value Tensile test Charpy impact test Bend test Macroscopic examination Corrosion test Sustained load cracking test Softening temperature test Glass transition temperature test Resin shear strength test Coating test Hydrogen compatibility test







Specifications for container tests Specified design value Burst Test Ambient Temperature Pressure Cycle Test LBB Performance Test Bonfire Test Penetration Test Chemical Exposure Test Composite Flaw Tolerance Test Accelerated Stress Rupture Test Extreme Temperature Pressure Cycle Test Impact Damage Test Leak Test Permeation Test Boss Torque Test Hydrogen Gas Cycling Test

PART 2

MODEL

Maximum format: A4 (210 × 297 mm)

EC TYPE-APPROVAL CERTIFICATE

Stamp of type-approval authority

Communication concerning:







— EC type-approval (1) of a type of hydrogen component — extension of EC type-approval (1) — refusal of EC type-approval (1) — withdrawal of EC type-approval (1) (1) Delete where not applicable

with regard to Regulation (EC) No 79/2009, as implemented by Regulation (EU) No 406/2010.

EC type-approval number:

Reason for extension:

SECTION I

0.1. Make (trade name of manufacturer):

0.2. Type:

0.3. Means of identification of type, if marked on the component ( 12 ) 0.3.1. Location of that marking:

0.5. Name and address of manufacturer:

0.7. In the case of components and separate technical units, location and method of affixing of the EC approval mark:

0.8. Name(s) and address(es) of assembly plant(s):

0.9. Name and address of the manufacturer's representative (if any):

SECTION II

1. Additional information (where applicable): see Addendum

2. Technical service responsible for carrying out the tests:

3. Date of test report:

4. Number of test report:

5. Remarks (if any): see Addendum

6. Place:

7. Date:

8. Signature: Attachments : Information package. Test report.



Addendum to EC type-approval certificate No … relating to EC component type-approval of a hydrogen component or system 1. Additional information 1.1. Hydrogen system designed to use liquid hydrogen / Hydrogen system designed to use compressed (gaseous) hydrogen / Hydrogen component designed to use liquid hydrogen / Hydrogen component designed to use compressed (gaseous) hydrogen ( 13 ) 2. Specifications and test results 2.1. Containers designed to use compressed (gaseous) hydrogen 2.1.1. Container material specifications



Material specification Applicable to Material Steel Aluminium alloy Plastic liner Fibre Resin Coating Details Material manufacturer Type of material Material identification Heat treatment definition Chemical composition Cold- or cryoforming procedure Welding procedure definition 2.1.2. Container material test results



Material test Applicable to Material Steel Aluminium alloy Plastic liner Fibre Resin Coating Specified material value Test value Tensile test Charpy impact test Bend test Macroscopic examination Corrosion test Sustained load cracking test Softening temperature test Glass transition temperature test Resin shear strength test Coating test Hydrogen compatibility test 2.1.3. Container test results



Container test Specified design value Test result Burst Test Ambient Temperature Pressure Cycle Test LBB Performance Test Bonfire Test Penetration Test Chemical Exposure Test Composite Flaw Tolerance Test Accelerated Stress Rupture Test Extreme Temperature Pressure Cycle Test Impact Damage Test Leak Test Permeation Test Boss Torque Test Hydrogen Gas Cycling Test 3. Restriction of use of the device (if any): 4. Remarks:

PART 3

EC component type-approval mark

1. The EC component type-approval mark shall consist of: 1.1. a rectangle surrounding the lower-case letter ‘e’ followed by the distinguishing letter(s) or number of the Member State which has granted the EC component type-approval:



1 For Germany 2 For France 3 For Italy 4 For the Netherlands 5 For Sweden 6 For Belgium 7 For Hungary 8 For the Czech Republic 9 For Spain 11 For the United Kingdom 12 For Austria 13 For Luxembourg 17 For Finland 18 For Denmark 19 For Romania 20 For Poland 21 For Portugaly 23 For Greece 24 For Ireland ►M1 25 For Croatia ◄ 26 For Slovenia 27 For Slovakia 29 For Estonia 32 For Latvia 34 For Bulgaria 36 For Lithuania 49 For Cyprus 50 For Malta 1.2. In the vicinity of the rectangle the ‘base approval number’ contained in Section 4 of the type-approval number preceded by the two figures indicating the sequence number assigned to this Regulation or the latest major technical amendment to Regulation (EC) No 79/2009 or this Regulation. For this Regulation, the sequence number is 00.

2. The component type-approval mark is affixed to the component or system in such a way as to be indelible and clearly legible.

3. An example of a component type-approval mark is contained in the Addendum.



Addendum to appendix 1 Example of a component type-approval mark Legend: the above component type-approval was issued by Belgium under number 0004. The first two digits (00) indicate that the component was approved according to this Regulation.









ANNEX III

Requirements for hydrogen components and systems designed to use liquid hydrogen and their installation on hydrogen powered vehicles

1. INTRODUCTION

This Annex sets out the requirements and test procedures for hydrogen components and systems designed to use liquid hydrogen and their installation on hydrogen powered vehicles.

2. GENERAL REQUIREMENTS

2.1. The materials used in a hydrogen component or system shall be compatible with hydrogen in its liquid and/or gaseous state according to section 4.11. of Part 3.

PART 1

Requirements for the installation of hydrogen components and systems designed to use liquid hydrogen on hydrogen powered vehicles

1. General requirements

1.1. All hydrogen components and systems shall be installed on the vehicle and connected in accordance with best practice.

1.2. The hydrogen system(s) shall show no leaks other than the boil-off at Maximum Allowable Working Pressure (MAWP), i.e. stay bubble-free if using leak-detecting spray.

1.3. The operating temperatures should be:



Internal combustion engine compartment On board (all types of propulsion systems) – 40 °C to + 120 °C – 40 °C to + 85 °C

1.4. Appropriate automatic measures shall be adopted in coordination with the refuelling station to ensure that no uncontrolled hydrogen release occurs during the filling procedure.

1.5. In the event of hydrogen leakage or venting, hydrogen shall not be allowed to accumulate in enclosed or semi-enclosed spaces of the vehicle.

2. Installation of the hydrogen container on-board of a vehicle

2.1. The container can be integrated into the vehicle design to provide complementary functions. In such cases the container shall be designed to fulfil the integrated function requirements and the container requirements set out in Part 2.

2.2. When the vehicle is ready for use the lowest part of the hydrogen container shall not reduce the ground clearance of the vehicle. This shall not apply if the hydrogen container is adequately protected, at the front and the sides, and no part of the hydrogen container is located lower than this protective structure.

2.3. The hydrogen container(s) including the safety devices affixed at it must be mounted and fixed so that the following accelerations can be absorbed without breaking of the fixation or loosening of the container(s) (demonstrated by testing or calculation). The mass used shall be representative for a fully equipped and filled container or container assembly. Vehicle of categories M1 and N1: (a) 20 g in the direction of travel (b) 8 g horizontally perpendicular to the direction of travel Vehicles of categories M2 and N2: (a) 10 g in the direction of travel (b) 5 g horizontally perpendicular to the direction of travel Vehicles of categories M3 and N3: (a) 6,6 g in the direction of travel (b) 5 g horizontally perpendicular to the direction of travel

2.4. The provisions of section 2.3 shall not apply if the vehicle is approved according to Directives 96/27/EC and 96/79/EC of the European Parliament and of the Council ( 14 ) ( 15 ).

3. Accessories fitted to the hydrogen container

3.1. Automatic shut-off valves or non-return valves

3.1.1. Automatic shut-off valves shall be used in compliance with section 6. of Annex VI to Regulation (EC) No 79/2009, except for the boil-off management system and shall be idle closed.

3.1.2. Refuelling connections or receptacles shall be used in compliance wit section 4. of Annex VI to Regulation (EC) No 79/2009.

3.1.3. In the event that the container is displaced, the first isolating device and, if applicable, the line connecting it to the container shall be protected in such a manner that the shut-off function remains operational and the connection between the device and the container cannot be ruptured.

3.1.4. The automatic valves shall be closed idle (fail-safe).

3.1.5. When another hydrogen conversion system is switched off, irrespective of the position of the activation switch, the fuel supply to the respective hydrogen conversion system shall be switched off and remain closed until the respective hydrogen conversion system is required to operate.

3.2. Pressure relief devices

3.2.1. The pressure triggered pressure relief devices shall be fitted to the hydrogen container(s) in such a manner that they must discharge into an atmospheric outlet line that vents outside the vehicle. They shall not discharge at a heat source such as the exhaust. Additionally they shall discharge such that hydrogen cannot enter the inside of the vehicle and/or accumulate in an enclosed space. Additionally the first pressure relief device shall not discharge into a partially enclosed space. In case the secondary pressure relief device is a burst disc and is installed within the inner tank, an appropriate exhaust vent in the outer jacket is required.

3.2.2. In the case of inner tanks, the normal operating range of the inner tank pressure is between 0 MPa and the set pressure of the primary safety relief device which is lower or equal to the Maximum Allowable Working Pressure (MAWP) of the inner tank.

3.2.3. In the case of steel inner tanks, the lower limit of the impermissible fault range corresponds to a pressure higher than 136 per cent of the Maximum Allowable Working Pressure (MAWP) of the inner tank if a safety valve is used as secondary pressure relief device. In case of steel inner tanks, the lower limit of the impermissible fault range corresponds to a pressure higher than 150 per cent of the Maximum Allowable Working Pressure (MAWP) of the inner tank if a burst disk is used as secondary pressure relief device. For other materials an equivalent level of safety is to be applied. The impermissible fault range shall be the pressure at which plastic deformation or bursting of the inner tank occurs as shown in Figure 3.2.

3.3. Gas tight housing on the hydrogen container(s)

3.3.1. All non-welded connections of hydrogen-carrying components and the hydrogen components which can leak, that are mounted within the passenger or luggage compartment or other non-ventilated compartment, shall be enclosed by a gas tight housing.

3.3.2. The gas tight housing shall be vented to the atmosphere.

3.3.3. The ventilation opening of the gas tight housing shall be at the highest point of the housing and shall not discharge at a heat source such as the exhaust. Additionally it shall discharge such that hydrogen cannot enter the inside of the vehicle and/or accumulate in an enclosed or partially enclosed space.

3.3.4. There shall be no unprotected ignition sources inside the gas tight housing.

3.3.5. Any connecting system and lead-through in the body of the vehicle for ventilation of the gas tight housing shall have at least the same cross sectional area as the tube of the pressure relief device.

3.3.6. This housing shall be for test purposes hermetically sealed and shall be gas tight at a pressure of 0,5 kPa, i.e. bubble-free for 1 minute and without any permanent deformation.

3.3.7. Any connecting system shall be secured by clamps, or other means, to the gas tight housing and the lead-through to ensure that a gas tight joint is formed.

4. Rigid and flexible fuel lines

4.1. Rigid fuel lines shall be secured such that they shall not be subjected to abrasion, critical vibration and/or other stresses.

4.2. Flexible fuel lines shall be secured such that they shall not be subjected to torsional stresses, abrasion is avoided and cannot be squeezed in normal use.

4.3. At the fixing points the fuel lines, flexible or rigid, shall be fitted in such a way that they cannot make a metal to metal contact to prevent galvanic and crevice corrosion.

4.4. Rigid and flexible fuel lines shall be routed to reasonably minimise exposure to accidental damage whether inside e.g. due to placing or movement of luggage or other loads, or outside the vehicle, e.g. due to rough ground or vehicle jacks etc.

4.5. At penetration through the vehicle body or other hydrogen components, the fuel lines shall be fitted with grommets or other protective material.

5. Fittings or gas connections between the components

5.1. Stainless steel tubes shall only be joined by stainless steel fittings.

5.2. The number of joints shall be limited to a minimum.

5.3. Any joints shall be made in locations where access is possible for inspection and leak testing.

5.4. In a passenger or enclosed luggage compartment, the fuel lines shall be no longer than reasonably required.

6. Refuelling connection or receptacle

6.1. The refuelling connection or receptacle shall be secured against maladjustment and shall be protected from dirt and water. It shall be safe against handing errors.

6.2. The refuelling connection or receptacle shall not be installed in the engine compartment, passenger compartment or in any other unventilated compartment.

6.3. The refuelling line shall be secured at the container as described in section 3.1.1.

6.4. The refuelling connection or receptacle shall have an isolating device according to section 3.1.2.

6.5. It shall be ensured that the propulsion system cannot be operated and the vehicle cannot move while the refuelling connection or receptacle is connected to the filling station.

7. Electrical installation

7.1. The electrical components of the hydrogen system shall be protected against overloads.

7.2. Power supply connections shall be tight against the ingress of hydrogen where hydrogen components are present or hydrogen leaks are possible.

8. Boil-off under normal conditions

8.1. Boil-off gases shall be rendered harmless by a boil-off management system.

8.2. The boil-off management system shall be designed to accept the boil-off rate of the container(s) under normal operating conditions.

8.3. At start-up and during the operation of the vehicle, a warning system shall be activated to warn the driver in the event of the boil off management system failure.

9. Other requirements

9.1. All pressure relief devices and vent line(s) shall be protected against vandalism so far as reasonably practicable.

9.2. The passenger compartment, the luggage compartment and all safety-critical components of the vehicle (e.g. the brake system, electrical insulation) shall be protected against adverse temperature effects due to the cryogenic fuel. Possible leakage of the cryogenic fuel shall be considered when assessing the protection that is required.

9.3. Flammable materials used in the vehicle shall be protected from liquefied air that may condense on un-insulated elements of the fuel system.

9.4. Failure of the heating circuit of the heat exchanger shall not cause leakage from the hydrogen system.

10. Safety instrumented systems

10.1. Safety instrumented systems shall be fail-safe, redundant or self-monitoring.

10.2. If the safety-instrumented systems under section 10.1. are fail-safe or self-monitoring electronic systems, the special requirements of Annex VI to this Regulation shall be applied.

11. Requirements for the inspection of the hydrogen system

11.1. Each hydrogen system shall be inspected at least every 48 months after the date of its entry into service, and at the time of any re-installation.

11.2. The inspection shall be performed by a technical service, in accordance with the manufacturers specifications set out in Part 3 of Annex I.

PART 2

Requirements for hydrogen containers designed to use liquid hydrogen

1. INTRODUCTION

This Part sets out the requirements and test procedures for hydrogen containers designed to use liquid hydrogen.

2. TECHNICAL REQUIREMENTS

2.1. The design validation of the container by calculation shall be done in accordance with EN 1251-2.

2.2. Mechanical stresses The parts of the container shall withstand the following mechanical stresses: 2.2.1. Inner tank 2.2.1.1. Test pressure The inner tank shall resist the test pressure Ptest: Ptest = 1,3 (MAWP + 0,1 MPa) with MAWP being the Maximum Allowable Working Pressure of the inner tank in MPa 2.2.1.2. Outer pressure If an operating mode of the inner tank and its equipment under vacuum is possible, the inner tank and its equipment shall resist an outer pressure of 0,1 MPa. 2.2.2. Outer jacket 2.2.2.1. The outer jacket shall resist the Maximum Allowable Working Pressure (MAWP), which is the set pressure of its safety device. 2.2.2.2. The outer jacket shall resist an outer pressure of 0,1 MPa. 2.2.3. Outer supports The outer supports of the full container shall resist the accelerations referred to in section 2.3 of Part 1 without rupture, in which case the allowable stress in the support elements calculated according to linear stress model shall not exceed: σ ≤ 0,5 Rm 2.2.4. Inner supports The inner supports of the full container shall resist the accelerations referred to in section 2.3 of Part 1 without rupture, in which case the allowable stress in the support elements calculated according to linear stress model shall not exceed: σ ≤ 0,5 Rm 2.2.5. The requirements of sections 2.2.3. and 2.2.4. do not apply if it can be demonstrated that the tank may support the accelerations referred to in section 2.3 of Part 1 without any leak on the inner tank and all the different pipes upstream of the automatic safety devices, shut off valves and/or non-return valves. 2.2.6. The proof of the dimensioning of the supports of the container can be done either by calculation or by experiment.

2.3. Design temperature 2.3.1. Inner tank and outer jacket The design temperature of the inner tank and the outer jacket shall be 20 °C. 2.3.2. Other equipment For all other equipment which is not mentioned under section 2.3.1. the design temperature is the lowest respectively the highest possible operating temperature set out in section 1.3. of Part 1. 2.3.3. The thermal stresses by operating conditions like filling or withdrawal or during the cooling down processes shall be considered.

2.4. Chemical compatibility 2.4.1. The materials of the container and its equipment shall be compatible with: (a) hydrogen, if the parts are in contact with it; (b) the atmosphere, if the parts are in contact with it; (c) any other media the parts are in contact with (i.e. coolant etc.).

3. MATERIALS

3.1. The materials shall be composed, manufactured and further treated in a manner that: (a) the finished products show the required mechanical properties (b) the finished products which are used for pressurised components and are in contact with hydrogen resist the thermal, chemical and mechanical stresses that they may be subjected to. In particular, the materials of the components in contact with cryogenic temperatures shall be compatible with cryogenic temperatures according to EN 1252-1.

3.2. Characteristics 3.2.1. Materials used at low temperatures shall follow the toughness requirements of EN 1252-1. For non-metallic materials low temperature suitability shall be validated by an experimental method, taking into account service conditions. 3.2.2. The materials used for the outer jacket shall ensure the integrity of the insulation system, and their elongation at fracture in a tensile test shall be at least 12 per cent at liquid nitrogen temperature. 3.2.3. A corrosion allowance is not required for the inner tank. A corrosion allowance is not required on other surfaces if they are adequately protected against corrosion.

3.3. Certificates and proofs of the material characteristics 3.3.1. The filler materials shall be compatible with the parent material so as to form welds with properties equivalent to those specified for the parent material for all temperatures that the material may encounter. 3.3.2. The manufacturer shall obtain and provide chemical cast analysis and mechanical properties certificates of the material in respect of the steels or other materials used in the construction of the parts subject to pressure. In case of metallic materials the certificate must be at least type 3.1 according to EN 10204 or equivalent. In case of non-metallic materials the certificate must be of equivalent type. 3.3.3. The technical service may carry out analyses and examinations. These examinations shall be carried out either on specimens taken from the materials as supplied to the manufacturer of the container or on the finished containers. 3.3.4. The manufacturer shall make available to the technical service the results of metallurgical and mechanical tests and analyses of parent and filler materials carried out on welds. 3.3.5. Material sheets shall be marked at least with: — sign of the manufacturer — material identification number — batch number — sign of the inspecting person

3.4. Design calculation 3.4.1. Provisions regarding the inner tank: The design of the inner tank shall be done according to the design rules of EN 1251-2. 3.4.2. Provisions regarding the outer jacket: The design of the outer jacket shall be done according to the design rules of EN 1251-2. 3.4.3. The general tolerances of ISO 2768-1 shall apply.

4. MANUFACTURING AND MOUNTING OF THE CONTAINER

4.1. Manufacturers of welded containers shall have a welding quality system in operation, taking into account the quality requirements for welding in accordance with EN 729-2:1994 or EN 729-3:1994.

4.2. The welding process shall be approved by the technical service in accordance with EN 288-3:1992/A1:1997, EN 288-4:1992/A1:1997 and EN 288-8:1995.

4.3. Welders shall be approved by the technical service according to EN 287-1:1992/A1:1997, EN 287-2:1992/A1:1997 and for automatic welding operators in accordance with EN 1418:1997.

4.4. Manufacturing operations (e.g. forming and heat treatment, welding) shall be carried out according to EN 1251-2.

4.5. The inspections and the testing of the internal pipe work between the inner tank and the outer jacket: all welded joints of the pipe work shall be subject to 100 per cent non-destructive inspection, wherever possible by radiographic inspection, alternatively ultrasonic test, liquid penetrant testing, helium leakage test, etc.

4.6. The number of joints should be minimised. Joints shall not be permitted within the void between the inner tank and the outer jacket unless they are welded or glued.

4.7. The equipment of the container shall be mounted in a way that the system and its components function in a correct and safe way and are gas tight.

4.8. The container shall be cleaned and dried before operation according to EN 12300.

5. OTHER REQUIREMENTS

5.1. Protection of the outer jacket

The outer jacket shall be protected by means of a device preventing bursting of the outer jacket or collapsing of the inner tank.

5.2. Provisions regarding the insulation

5.2.1. Under no circumstances may ice be allowed to form on the outer wall of the container under normal operating conditions. At the area of pressure relief pipe, local ice formation is allowed on the outside of the pipe.

5.3. Level gauge

5.3.1. A measuring gauge in the driver's compartment shall indicate the level of liquid in the container with an accuracy of +/- 10 per cent.

5.3.2. If the system comprises a float, the latter shall withstand an outside pressure greater than the Maximum Allowable Working Pressure (MAWP) of the inner tank with a minimum coefficient of safety of 2 with respect to the buckling failure criteria.

5.4. Maximum filling level

5.4.1. A system shall be provided for preventing the container from being overfilled. This system may work in conjunction with the refuelling station. This system shall bear a permanent marking, indicating the container-type for which it has been designed and if applicable the mounting position and orientation.

5.4.2. The filling process shall not lead to any pressure relief device coming into operation irrespective of time passed during/after the filling process. The filling process shall not lead to operating conditions the BMS (boil-off management system) is not designed for and therefore cannot handle.

5.5. Marking

5.5.1. In addition to the EC component type-approval mark set out in Part 3 of Annex II, every container shall also bear a marking with the following data clearly legible: 5.5.1.1. The inner tank: (a) the name and address of inner tank manufacturer, (b) the serial number. 5.5.1.2. The outer jacket: (a) a label as set out in section 3.1 of Annex V; (b) a prohibition of additional welding, milling and stamping; (c) an allowed orientation of the tank in the vehicle; (d) an identification plate with the following information: i. name of the manufacturer ii. serial number iii. water volume in litres iv. Maximum Allowable Working Pressure (MAWP) [MPa] v. year and month of manufacturing (e.g. 2009/01) vi. operating temperature range the identification plate shall be legible while installed.

5.5.2. The marking method shall not cause localised stress peaks in the structure of the inner tank or the outer jacket.

5.6. Inspection openings

Inspection openings are not required in the inner or outer jacket.

6. TESTS AND INSPECTION

6.1. Tests and inspection for the approval

For the approval, the technical service shall perform the tests and inspections according to sections 6.3.1. to 6.3.6. on two samples of containers. The samples shall be provided in the applicable state necessary for the inspections. For the approval, samples of the container shall be subjected to the tests according to sections 6.3.7. to 6.3.9. and shall be witnessed by the technical service.

6.2. Tests and inspection during production

The tests and inspections according to sections 6.3.1. to 6.3.6. shall be performed on each container.

6.3. Testing procedures

6.3.1. Pressure test

6.3.1.1. The inner tank and the pipe work situated between the inner tank and the outer jacket shall withstand an inner pressure test at room temperature any suitable media, according to the following requirements. The test pressure ptest shall be: ptest = 1,3 (MAWP + 0,1 MPa) with MAWP being the Maximum Allowable Working Pressure of the inner tank in MPa.

6.3.1.2. The pressure test shall be performed before the outer jacket is mounted.

6.3.1.3. The pressure in the inner tank shall be increased at a constant rate until the test pressure is reached.

6.3.1.4. The inner tank must remain under the test pressure at least for 10 minutes to establish that the pressure is not reducing.

6.3.1.5. After the test the inner tank must not show any signs of visible permanent deformation or visible leaks.

6.3.1.6. Any inner tank tested which does not pass the test because of permanent deformation shall be rejected and shall not be repaired.

6.3.1.7. Any inner tank tested which does not pass the test because of leakage may be accepted after repair and retesting.

6.3.1.8. In case of hydraulic test, upon completion of this test, the container shall be emptied and dried until the dew point inside the container is – 40 °C according to EN 12300.

6.3.1.9. A test report shall be drawn up and the inner tank shall be marked by the inspection departments if accepted.

6.3.2. Leak testing

After final assembly the hydrogen container shall be leak tested with a gas mixture containing a minimum of 10 per cent of helium

6.3.3. Verification of the dimensions

The following dimensions shall be verified:

— for cylindrical container(s) roundness of the inner tank according to EN 1251-2:2000, 5.4

— departure from a straight line of the inner and outer jacket according to EN 1251-2, 5.4

6.3.4. Destructive and non-destructive tests of welding seams

The tests shall be performed according to EN 1251-2.

6.3.5. Visual inspection

The welding seams and the inner and outer surfaces of the inner and outer jackets of the container shall be inspected visually. The surfaces shall not show any critical damages or defaults.

6.3.6. Marking

The marking shall be verified in accordance with section 5.5.

6.3.7. Burst test

The burst test shall be performed on one sample of the inner tank, not integrated in its outer jacket and not insulated.

6.3.7.1. Criteria

6.3.7.1.1. The burst pressure shall be at least equal to the burst pressure used for the mechanical calculations. For steel tanks that is: (a) either the Maximum Allowable Working Pressure (MAWP) (in MPa) plus 0,1 MPa multiplied by 3,25; (b) or the Maximum Allowable Working Pressure (MAWP) (in MPa) plus 0,1 MPa multiplied by 1,5 and multiplied by Rm/Rp, where Rm means minimum ultimate tensile strength and Rp means minimum yield strength.

6.3.7.1.2. Hydrogen containers made from materials other than steel shall be demonstrated to perform as safely as containers complying with the requirements set out in points 6.3.7.1.1. and 6.3.7.1.2.

6.3.7.2. Procedure

6.3.7.2.1. The tested tank shall be representative of the design and the manufacturing of the type to be approved.

6.3.7.2.2. The test shall be a hydraulic test.

6.3.7.2.3. The tube and piping may be modified to enable the test (purge of dead volume, introduction of the liquid, closing of non-used pipes, etc.)

6.3.7.2.4. The tank shall be filled with water. The pressure shall be increased at a constant rate not exceeding 0,5 MPa/min until burst. When the Maximum Allowable Working Pressure (MAWP) is reached there shall be a wait period of at least ten minutes at constant pressure so that the deformation of the tank shall be checked.

6.3.7.2.5. A system shall enable to look at possible deformations.

6.3.7.2.6. The pressure shall be recorded or written during the entire test.

6.3.7.3. Results

The test conditions and the bursting pressure shall be written in a test certificate signed by the manufacturer and the technical service.

6.3.8. Bonfire test

6.3.8.1. Criteria

6.3.8.1.1. The tank shall not burst and the pressure inside the inner tank shall not exceed the permissible fault range of the inner tank. In case of steel inner tanks, the secondary pressure relief device shall limit the pressure inside the tank to 136 per cent of the Maximum Allowable Working Pressure (MAWP) of the inner tank, if a safety valve is used as secondary pressure relief device. In case of steel inner tanks, the secondary pressure relief device shall limit the pressure inside the tank to 150 per cent of the Maximum Allowable Working Pressure (MAWP) of the inner tank, if a burst disk is used outside the vacuum area as secondary pressure relief device. In case of steel inner tanks, the secondary pressure relief device shall limit the pressure inside the tank to 150 per cent of the Maximum Allowable Working Pressure plus 0,1 MPa (MAWP + 0,1 MPa) of the inner tank, if a burst disk is used inside the vacuum area as secondary pressure relief device. For other materials, an equivalent level of safety shall be demonstrated. The secondary pressure relief device shall not operate below 110 per cent of the set pressure of the primary pressure relief device.

6.3.8.2. Procedure

6.3.8.2.1. The tested tank shall be representative of the design and the manufacturing of the type to be approved.

6.3.8.2.2. Its manufacturing shall be completely finished and it shall be mounted with all its equipment.

6.3.8.2.3. The tank shall already be cooled down and the inner tank shall be at the same temperature as the liquid hydrogen. The tank shall have contained during the previous 24 hours a volume of liquid hydrogen at least equal to half of the water volume of the inner tank. 6.3.8.2.3.1. The tank shall be filled with liquid hydrogen so that the quantity of liquid hydrogen measured by the mass measurement system shall be half of the maximum allowed quantity that may be contained in the inner tank. 6.3.8.2.3.2. A fire shall burn 0,1 m underneath the tank. The length and the width of the fire shall exceed the plan dimensions of the container by 0,1 m. The temperature of the fire shall be at least 590 °C. The fire shall continue to burn for the duration of the test. 6.3.8.2.3.3. The pressure of the tank at the beginning of the test shall be between 0 MPa and 0,01 MPa at the boiling point of hydrogen in the inner tank. 6.3.8.2.3.4. Once the safety device opens, the test shall continue until the blow off of the safety device has finished. During the test the tank shall not burst and the pressure inside the inner tank shall not exceed the permissible fault range of the inner tank. In the case of steel inner tanks, the tank pressure shall not exceed 136 per cent of the Maximum Allowable Working Pressure (MAWP) of the inner tank. For other materials, an equivalent level of safety shall be applied.

6.3.8.3. Results

The test conditions and the maximum pressure reached within the tank during the test shall be recorded in a test certificate signed by the manufacturer and the technical service.

6.3.9. Maximum filling level test

6.3.9.1. Criteria

During all the tests necessary for approval, the filling process shall not lead to any pressure relief device coming into operation irrespective of time passed during/after the filling process. The filling process shall not lead to operating conditions the BMS (boil-off management system) is not designed for and therefore cannot handle.

6.3.9.2. Procedure

6.3.9.2.1. The tested tank shall be representative of the design and the manufacturing of the type to be approved.

6.3.9.2.2. Its manufacturing shall be completely finished and it shall be fitted with all its equipment and particularly the level gauge.

6.3.9.2.3. The tank shall already be cooled down and the inner tank shall be at the same temperature as the liquid hydrogen. The tank shall have contained during the previous 24 hours a volume of liquid hydrogen at least equal to half of the water volume of the inner tank.

6.3.9.2.4. The mass of hydrogen or the mass flow rate at the inlet and the outlet of the tank shall be measured with an accuracy better than 1 per cent of the maximum filling mass of the tested container

6.3.9.2.5. The tank shall be completely filled 10 times with liquid hydrogen at equilibrium with its vapour. Between each filling at least a quarter of the liquid hydrogen of the tank shall be emptied.

6.3.9.3. Results

The test conditions and the ten maximum level measured by the added system shall be written in a test certificate signed by the manufacturer and the technical service.

PART 3

Requirements for hydrogen components other than containers designed to use liquid hydrogen

1. INTRODUCTION

This Part sets out the requirements and test procedures for hydrogen components other than containers designed to use liquid hydrogen.

2. GENERAL REQUIREMENTS

2.1. Materials used in hydrogen components shall be compatible with hydrogen in accordance with section 4.11.

2.2. The hydrogen system upstream of the first pressure regulator, excluding the hydrogen container, shall have a Maximum Allowable Working Pressure (MAWP) equal to the maximum pressure the component is subjected to but at least 1,5 times the set pressure of the primary safety relief device of the inner tank and a coefficient of safety not less than that of the inner tank.

2.3. Components downstream of pressure regulator(s) shall be protected against over-pressurisation and shall be designed for at least 1,5 times the outlet pressure (Maximum Allowable Working Pressure (MAWP)) of the first pressure regulator upstream.

2.4. The insulation of the components shall prevent liquefaction of the air in contact with the outer surfaces, unless a system is provided for collecting and vaporising the liquefied air. Then the materials of the components nearby shall be compatible with an atmosphere enriched with oxygen according to EN 1797.

3. TECHNICAL REQUIREMENTS

3.1. Pressure relief devices

3.1.1. Pressure relief devices for the inner tank

3.1.1.1. The primary pressure relief device for the inner tank shall limit the pressure inside the tank to not more than 110 per cent of the Maximum Allowable Working Pressure (MAWP), even in case of a sudden vacuum loss. This device shall be a safety valve or equivalent and shall be connected directly to the gaseous part under normal operating conditions.

3.1.1.2. The secondary pressure relief device for the inner tank shall be installed to ensure that the pressure in the tank cannot under any circumstances exceed the permissible fault range of the inner tank. In the case of steel inner tanks, the secondary pressure relief device shall limit the pressure in the tank to 136 per cent of the Maximum Allowable Working Pressure (MAWP) of the inner tank, if a safety valve is used as secondary pressure relief device. In case of steel inner tanks, the secondary pressure relief device shall limit the pressure in the tank to 150 per cent of the Maximum Allowable Working Pressure (MAWP) of the inner tank, if a burst disk is used outside the vacuum area as secondary pressure relief device. In case of steel inner tanks, the secondary pressure relief device shall limit the pressure in the tank to 150 per cent of the Maximum Allowable Working Pressure plus 0,1 MPa (MAWP + 0,1 MPa) of the inner tank, if a burst disk is used inside the vacuum area as secondary pressure relief device. For other materials, an equivalent level of safety shall be demonstrated. The secondary pressure relief device shall not operate below 110 per cent of the set pressure of the primary pressure relief device.

3.1.1.3. The sizing of the safety devices shall be done in accordance with EN 13648-3.

3.1.1.4. The two devices referred to in sections 3.1.1.1. and 3.1.1.2. may be connected to the inner tank by the same fuel line.

3.1.1.5. The rating of the pressure relief devices shall be clearly marked. Tampering with the devices shall be prevented by means of a lead seal or equivalent system.

3.1.1.6. Pressure relief valves shall, after discharge, close at a pressure higher than 90 per cent of the set pressure of the pressure relief valve. They shall remain closed at all lower pressures.

3.1.1.7. Pressure relief valves shall be installed on the gaseous fraction area of the hydrogen tank.

3.1.2. Pressure relief devices for other components

3.1.2.1. Whenever there is a risk of cryogenic liquid or vapour becoming trapped between two items of equipment on a line, a pressure relief device or a measure ensuring an equivalent level of safety shall be provided.

3.1.2.2. Upstream of the first pressure regulator the set pressure of the safety device which prevents over-pressurisation shall not exceed the Maximum Allowable Working Pressure (MAWP) of the lines and shall not be less than 120 per cent of the Maximum Allowable Working Pressure (MAWP) of the tank, to prevent such valves opening instead of the pressure relief devices for the inner tank.

3.1.2.3. The rating of pressure relief devices downstream of the pressure regulator(s) shall not exceed the Maximum Allowable Working Pressure (MAWP) of the components downstream of the pressure regulator.

3.1.2.4. Pressure relief valves shall, after discharge, close at a pressure higher than 90 per cent of the set pressure of the pressure relief valve. They shall remain closed at all lower pressures.

3.1.3. Provisions regarding the approval of pressure relief devices

3.1.3.1. The design, manufacturing and control of the pressure relief devices shall be in accordance with EN 13648-1 and EN 13648-2.

3.1.3.2. In case of boil off system in parallel of the primary safety device, then the safety valve shall be a category B safety device otherwise it shall be a category A safety device according to EN 13648.

3.1.3.3. Maximum Allowable Working Pressure (MAWP): 1,5 × Maximum Allowable Working Pressure (MAWP) of the inner tank or maximum pressure the component is subjected to.

3.1.3.4. Set pressure 3.1.3.4.1. Primary devices of the inner tank: according to section 3.1.1.1. 3.1.3.4.2. Secondary device of the inner tank: according to section 3.1.1.2. 3.1.3.4.3. Pressure relief devices for components other than the tank: according to section 3.1.2.

3.1.3.5. Design temperatures 3.1.3.5.1. External temperature: according to section 1.3 of Part 1. 3.1.3.5.2. Internal temperature: – 253 °C to + 85 °C.

3.1.3.6. Applicable test procedures:



Pressure test section 4.2 External leakage test section 4.3 Operational test section 4.5 Corrosion resistance section 4.6, only for metallic parts, only for equipment outside of the gas tight housing Temperature cycle test section 4.9, only for non-metallic parts

3.1.4. Lines incorporating pressure relief devices

3.1.4.1. No isolating device shall be installed between the protected component and the pressure relief device.

3.1.4.2. The lines before and behind the pressure relief devices shall not impede their function and shall be compatible with the criteria defined in sections 3.1.1. to 3.1.3.

3.2. Valves

3.2.1. Provisions regarding the approval of hydrogen valves

3.2.1.1. The design, manufacturing and checking of the cryogenic hydrogen valves shall be in accordance with EN 13648-1 and EN 13648-2.

3.2.1.2. Maximum Allowable Working Pressure (MAWP): 1,5 × Maximum Allowable Working Pressure (MAWP) of the inner tank or maximum pressure the valve is subjected to.

3.2.1.3. Design temperatures 3.2.1.3.1. External temperature: according to section 1.3 of Part 1. 3.2.1.3.2. Internal temperature: – 253 °C to + 85 °C for valves before the heat exchanger – 40 °C to + 85 °C for valves after the heat exchanger

3.2.1.4. Applicable test procedures:



Pressure test section 4.2 External leakage test section 4.3 Endurance test section 4.4 (with 6 000 operation cycles for manual valves with 20 000 operation cycles for automatic valves) Corrosion resistance section 4.6, only for metallic parts, only for equipment outside of the gas tight housing Resistance to dry-heat section 4.7, only for non-metallic parts Ozone ageing section 4.8, only for non-metallic parts Temperature cycle test section 4.9, only for non-metallic parts Seat leakage test section 4.12

3.3. Heat exchangers

3.3.1. Notwithstanding the provision of section 2.1. the Maximum Allowable Working Pressure (MAWP) of the heat exchanger shall be the highest Maximum Allowable Working Pressure (MAWP) of the different circuits.

3.3.2. The exhaust gases from the propulsion system shall not under any circumstances be used directly in the heat exchanger.

3.3.3. A safety system shall be provided to: prevent failure of the heat exchanger; and prevent any cryogenic liquid or gas from entering the other circuit and the system located downstream of it, if it has not been designed for this.

3.3.4. Provisions regarding the approval of hydrogen valves 3.3.4.1. Maximum Allowable Working Pressure (MAWP): 1,5 × Maximum Allowable Working Pressure (MAWP) of the inner tank or maximum pressure the component is subjected to. 3.3.4.2. Design temperatures 3.3.4.2.1. External temperature: according to section 1.3 of Part 1. 3.3.4.2.2. Internal temperature: – 253 °C to + 85 °C. 3.3.4.3. Applicable test procedures



Pressure test section 4.2 External leakage test section 4.3 Corrosion resistance section 4.6, only for metallic parts Resistance to dry-heat section 4.7, only for non-metallic parts Ozone ageing section 4.8, only for non-metallic parts Temperature cycle test section 4.9, only for non-metallic parts 3.3.4.4. The manufacturing and mounting of the heat exchanger shall be certified according to sections 4.3. to 4.5 of Part 2.

3.4. Refuelling connections or receptacles

3.4.1. The refuelling connections or receptacles shall be protected against contamination.

3.4.2. Provisions regarding the approval of refuelling connections or receptacles 3.4.2.1. Maximum Allowable Working Pressure (MAWP): 1,5 × Maximum Allowable Working Pressure (MAWP) of the inner tank or maximum pressure the component is subjected to. 3.4.2.2. Design temperatures 3.4.2.2.1. External temperature: according to section 1.3 of Part 1. 3.4.2.2.2. Internal temperature: – 253 °C to + 85 °C 3.4.2.3. Applicable test procedures



Pressure test section 4.2 External leakage test section 4.3 Endurance test section 4.4 (with 3 000 operation cycles) Corrosion resistance section 4.6, only for metallic parts Resistance to dry-heat section 4.7, only for non-metallic parts Ozone ageing section 4.8, only for non-metallic parts Temperature cycle test section 4.9, only for non-metallic parts Seat leakage test section 4.12

3.5. Pressure regulators

3.5.1. Provisions regarding the approval of pressure regulators

3.5.1.1. Maximum Allowable Working Pressure (MAWP): 1,5 × Maximum Allowable Working Pressure (MAWP) of the inner tank or maximum pressure the component is subjected to.

3.5.1.2. Design temperatures 3.5.1.2.1. External temperature: according to section 1.3 of Part 1. 3.5.1.2.2. Internal temperature: at least as given in section 1.3 of Part 1.

3.5.1.3. Applicable test procedures



Pressure test section 4.2 External leakage test section 4.3 Endurance test section 4.4 (with 20 000 operation cycles) Corrosion resistance section 4.6, only for metallic parts, only for equipment outside of the gas tight housing Resistance to dry-heat section 4.7, only for non-metallic parts Ozone ageing section 4.8, only for non-metallic parts Temperature cycle test section 4.9, only for non-metallic parts Seat leakage test section 4.12

3.6. Sensors

3.6.1. Provisions regarding the approval of sensors

3.6.1.1. Maximum Allowable Working Pressure (MAWP): 1,5 × Maximum Allowable Working Pressure (MAWP) of the inner tank or maximum pressure the component is subjected to.

3.6.1.2. Design temperatures 3.6.1.2.1. If operated with ambient temperature: according to section 1.3 of Part 1. 3.6.1.2.2. If operated with cryogenic temperature: lowest operating temperature: – 253 °C, maximum temperature: + 85 °C or + 120 °C as given in section 1.3 of Part 1.

3.6.1.3. Applicable test procedures



Pressure test section 4.2, only for equipment directly in contact with hydrogen External leakage test section 4.3, only for equipment directly in contact with hydrogen Corrosion resistance section 4.6, only for metallic parts, only for equipment outside of the gas tight housing Resistance to dry-heat section 4.7 Ozone ageing section 4.8, only for non-metallic parts Temperature cycle test section 4.9, only for non-metallic parts

3.7. Flexible fuel lines

3.7.1. Provisions regarding the approval of flexible fuel lines

3.7.1.1. The design, manufacturing and control of the cryogenic flexible fuel lines shall be in accordance with EN 12434.

3.7.1.2. Maximum Allowable Working Pressure (MAWP): 1,5 × Maximum Allowable Working Pressure (MAWP) of the inner tank or maximum pressure the component is subjected to.

3.7.1.3. Design temperatures 3.7.1.3.1. If operated with ambient temperature: according to section 1.3 of Part 1. 3.7.1.3.2. If operated with cryogenic temperature: lowest operating temperature: – 253 °C, maximum temperature: + 85 °C or + 120 °C as given in section 1.3 of Part 1.

3.7.1.4. Applicable test procedures



Pressure test section 4.2 External leakage test section 4.3 Corrosion resistance section 4.6, only for metallic parts, only for equipment outside of the gas tight housing Resistance to dry-heat section 4.7, only for non-metallic parts Ozone ageing section 4.8, only for non-metallic parts Temperature cycle test section 4.9, only for non-metallic parts Pressure cycle section 4.10

3.8. Provisions regarding electrical components of the hydrogen system

3.8.1. To prevent electric sparks: (a) electrically operated devices containing hydrogen shall be insulated in a manner that no current passes through hydrogen containing parts; (b) the electrical system of the electrically operated device shall be insulated from the body of the vehicle; (c) the electric circuit insulation resistance (batteries and fuel cells excluded), shall exceed 1 kΩ for each volt of the nominal voltage.

3.8.2. In case of power supply bushing to establish an isolated and tight electrical connection, the electric connection shall be of a hermetic sealed type.

4. TEST PROCEDURES

4.1. General provisions

4.1.1. Leakage tests shall be conducted with pressurised gas such as air or nitrogen containing at least 10 per cent helium.

4.1.2. Water or another fluid may be used to obtain the required pressure for pressure test.

4.1.3. All test records shall indicate the type of test medium used, if applicable.

4.1.4. The test period for leakage and pressure tests shall be not less than 3 minutes more than the response time of the sensor.

4.1.5. All tests shall be performed at ambient temperature, unless otherwise stated.

4.1.6. The different components shall be correctly dried before leak test.

4.2. Pressure test

4.2.1. A hydrogen containing component shall withstand without any visible evidence of leak or deformation a test pressure of 1,5 times its Maximum Allowable Working Pressure (MAWP) with the outlets of the high pressure part plugged. The pressure shall then be increased from 1,5 to 3 times the Maximum Allowable Working Pressure (MAWP). The component shall not show any visible evidence of rupture or cracks.

4.2.2. The pressure supply system shall be equipped with a positive shut-off valve and a pressure gauge, having a pressure range of not less than 1,5 times nor more than 2 times the test pressure and the accuracy of the gauge shall be 1 per cent of the pressure range.

4.2.3. For components requiring a leakage test, this test shall be performed prior to the pressure test.

4.3. External leakage test

4.3.1. A component shall be free from leakage through stem or body seals or other joints, and shall not show evidence of porosity in casting when tested as described in section 4.4.3. at any gas pressure between zero and its Maximum Allowable Working Pressure (MAWP).

4.3.2. The test shall be performed on the same equipment at the following conditions: 4.3.2.1. at ambient temperature; 4.3.2.2. at the minimum operating temperature or at liquid nitrogen temperature after sufficient conditioning time at this temperature to ensure thermal stability; 4.3.2.3. at the maximum operating temperature after sufficient conditioning time at this temperature to ensure thermal stability.

4.3.3. During this test the equipment under test shall be connected to a source of gas pressure. A positive shut-off valve and a pressure gauge having a pressure range of not less than 1,5 times nor more than 2 times the test pressure shall be installed in the pressure supply piping and the accuracy of the gauge shall be 1 per cent of the pressure range. The pressure gauge shall be installed between the positive shut-off valve and the sample under test.

4.3.4. Throughout the test, the sample shall be tested for leakage, with a surface active agent without formation of bubbles or measured with a leakage rate less than 10 cm3/hour.

4.4. Endurance test

4.4.1. A hydrogen component shall be capable of conforming to the applicable leakage test requirements of sections 4.3. and 4.12., after being subjected to the number of operation cycles specified for that component in sections 3.1. to 3.7. of Part 3.

4.4.2. The appropriate tests for external leakage and seat leakage, as described in sections 4.3. and 4.12. shall be carried out immediately following the endurance test.

4.4.3. The component shall be securely connected to a pressurised source of dry air or nitrogen and subjected to the number of cycles specified for that specific component in sections 3.1. to 3.7. of Part 3. A cycle shall consist of one opening and one closing of the component within a period of not less than 10 ± 2 seconds.

4.4.4. The component shall be operated through 96 per cent of the number of specified cycles at ambient temperature and at the MAWP of the component. During the off cy