2nd International Hydrogen Conference on Hydrogen Safety. San Sebastián, Spain – 11.-13. Sept. 2007. Hydrogen Safety. New Challenges based on BMW Hydrogen

2nd International Hydrogen Conference on Hydrogen Safety.San Sebastián, Spain – 11.-13. Sept. 2007.

Hydrogen Safety.New Challenges based on BMW Hydrogen 7.

Christian MüllerAutomotive Functional Safety.

Hydrogen SafetyChristian MüllerBMW Group12.09.2007Page 2

BMW Hydrogen Safety.Outline.

– Introduction

– Hydrogen 7- Hydrogen System- Safety Concept- Functional and Crash Tests

– New Challenges- Parking in Enclosed Areas- Degrading Concept of a Mono-Fuel Car

– Outlook


BMW Hydrogen 7.The Product Development Process.

Series Development

Qualification for H2 components and systems

First BMW H2 vehicle provided to users

Technical Goals Hydrogen 7


BMW Hydrogen 7.Hydrogen Technology Features.

LH2-Storage System Vehicle H2-Powertrain

New components

Adapted components

Bi-fueled internal combustion engine

Adapted ignition systemHydrogen gas warning system

CFK strengthening in side frame

Control System

Boil-off-ManagementSystem

LH2 fuel tank system

LH2 coupling system

Digital Motor Electronics (DME)

H2 mixture generation system


BMW Hydrogen 7.Hydrogen Protection Measures.

High reliability of operation

Fault-tolerant design

Safety functions

Warning

Fault Prevention

Fault Control & Damage Mitigation


BMW Hydrogen 7 Safety Features.Gas Warning System with H2 Sensors.

1....... Engine compartment2....... Passenger compartment3....... Rear shelf panel

4..... LH2 tank coupling5..... Barrier concept

A-D: Locking buttons at all doors, which display a flashing red light.


BMW Hydrogen 7 Safety Features.System and Component Tests.


BMW Hydrogen 7 Safety Features.Crash Tests.

FMVSS 30170% Offset right, 80 km/h

Car-to-Pole at tank coupling30 km/h


Car-to-Pole at tank coupling30 km/hResult: no leakage from the H2 system.

FMVSS 30170% Offset right, 80 km/hResult: no leakage from the H2 system.

BMW Hydrogen 7 Safety Features.Crash Test Results.


BMW Hydrogen 7 Safety Features.Crash Tests.

Truck overrideBarrier height 700 mm70 km/h (EES 45 km/h)


BMW Hydrogen 7 Safety Features.Crash Test Results.

Truck override, Barrier height 700 mm, 70 km/h (EES 45 km/h)Result: no leakage from the H2 system.


BMW Hydrogen 7 Safety Features.Vehicle Tests.

Tests throughout the year:

- High speed routes

- Testing in cold regions

- Testing in hot regions

> 1.4 million testing-kilometres

H2 technology - tested for the user.


BMW Hydrogen – New Challenges.Parking in Enclosed Areas.

*Conservatively estimated critical value based on diffusion experiments with up to 600g/h (Source : Dr. Michael Swain, University of Miami, in 1998) H=2,19 m

H=2,11 m

B=2,85 m L=5,8 m

Objective:Unrestricted parking in enclosed

areas.

H2 limits to be controlled:

Normal Case < 5 g/hBoil Off < 20 g/hUncritical amount <

200 g/h

Critical amount > 200 g/h*



Safety goal: Prevent severe injury due to emission of critical quantity of H2 in enclosed areas.

Risks

Requirements

Measures

H2-emission>> 200 g/h

critical H2

mixture in room

Ignition /explosion while

humans are exposed in

danger zone

Prevent emission of critical H2 quantity

Prevent formation of

critical mixture

Evacuate danger zone in time

- Vacuum stability

- Vacuum monitoring

- Delay H2 emission

- Generate emergency call

Warning (optical, acoustic, olfactory)



* HySafe, InsHyde, HyGarage, NIP, …

Project Topics

- Parameter studies for H2 emission scenarios in vehicle environment

- Experimental studies of H2-diffusion in enclosed rooms.

- More detailed, realistic CFD models for garage types

- Conditions and consequences of an ignition.

- Quality criteria for garages.

funded projects*

We need to know

how to evaluate and classify the criticality of H2 air mixtures in different garage types, depending on

- rate and speed of emitted H2

- total amount of emitted H2

- position and geometry of H2 outlet

- garage size and architecture

- garage ventilation


BMW Hydrogen – New Challenges.Degrading Concept of a Mono-Fuel Car.

Severi

ty o

f D

efe

cts

e.g. in case of a defective sensor

Request for service /

maintenance

e.g.: replacing defective

sensor

e.g. in case of icing of coolant heat exchanger

Functional degradation

e.g.: no fueling; reducing

engine power; no driving in

enclosed areasH2 alarm

in double barrier

Pre-warned shut-off

H2 alarm in

compartment

Immediate shut-off


BMW Hydrogen – New Challenges.Outlook.

For a safe hydrogen future, we need …

- Common international standards for H2 safety technology

- clearly defined constraints for the vehicle environment

(public/private garages, fuelling stations, workshops …)

- Operationally tested, reliable automotive H2 components

Documents

2nd International Hydrogen Conference on Hydrogen Safety. San Sebastián, Spain – 11.-13. Sept. 2007. Hydrogen Safety. New Challenges based on BMW Hydrogen