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Where fitted to a hydrogen-powered vehicle, the following hydrogen components must be type-approved:
components designed to use liquid hydrogen:
container;
automatic shut-off valve;
check valve or non-return valve (if used as a safety device);
flexible fuel line (if upstream of first automatic shut-off valve or other safety devices);
heat exchanger;
manual or automatic valve;
pressure regulator;
pressure relief valve;
pressure, temperature and flow sensors (if used as a safety device);
refuelling connection or receptacle;
hydrogen leakage detection sensors;
components designed to use compressed (gaseous) hydrogen with a nominal working pressure of over 3,0 MPa:
container;
automatic shut-off valve;
container assembly;
fittings;
flexible fuel line;
heat exchanger;
hydrogen filter;
manual or automatic valve;
non-return valve;
pressure regulator;
pressure relief device;
pressure relief valve;
refuelling connection or receptacle;
removable storage system connector;
pressure, temperature, hydrogen and flow sensors (if used as a safety device);
hydrogen leakage detection sensors.
Type of test |
---|
Burst test |
Bonfire test |
Maximum filling level test |
Pressure test |
Leak test |
The test procedures to be applied for the type-approval of hydrogen containers designed to use liquid hydrogen must include:
Burst test: the purpose of the test is to provide evidence that the hydrogen container does not fail before a specified level of high pressure, the burst pressure (safety factor multiplied by the MAWP) is exceeded. In order to obtain type-approval, the value of the real burst pressure during the test must exceed the required minimum burst pressure.
Bonfire test: the purpose of the test is to provide evidence that the container with its fire protection system does not burst when tested under specified fire conditions.
Maximum filling level test: the purpose of the test is to provide evidence that the system, which prevents overfilling of the container, works adequately and that the level of hydrogen during the filling procedure never causes the opening of the pressure relief devices.
Pressure test: the purpose of the test is to provide evidence that the hydrogen container can withstand a specified level of high pressure. In order to prove this, the container is pressurised to a given value for a specified time. After the test the container must not show any signs of visible permanent deformation or visible leaks.
Leak test: the purpose of the test is to provide evidence that the hydrogen container does not show evidence of leakage under specified conditions. In order to prove this, the container is pressurised to its nominal working pressure. It must not show any evidence of leakage detected through cracks, pores or other similar defects.
Subject to specific requirements in relation to any of the hydrogen components, the test procedures to be applied for the type-approval of hydrogen components, other than containers, designed to use liquid hydrogen must include:
Pressure test: the purpose of the test is to provide evidence that the hydrogen components can withstand a level of pressure which is higher than the working pressure of the component. The hydrogen components must not show any visible evidence of leak, deformation, rupture or cracks when the pressure is increased to a certain level.
External leakage test: the purpose of the test is to provide evidence that the hydrogen components are free from external leakage. The hydrogen components must not show evidence of porosity.
Endurance test: the purpose of the test is to provide evidence that the hydrogen components are capable of continuous reliable operation. The test consists of carrying out a specific number of test cycles for the hydrogen component under specified temperature and pressure conditions. A test cycle means the normal operation (i.e. one opening and one closing) of the hydrogen component.
Operational test: the purpose of the test is to provide evidence that the hydrogen components are capable of operating reliably.
Corrosion resistance test: the purpose of the test is to provide evidence that the hydrogen components are capable of resisting corrosion. In order to prove this, the hydrogen components are submitted to contact with specified chemicals.
Resistance to dry-heat test: the purpose of the test is to provide evidence that the non-metallic hydrogen components are capable of resisting high temperature. In order to prove this, the components are exposed to air at the maximum operating temperature.
Ozone ageing test: the purpose of the test is to provide evidence that the non-metallic hydrogen components are capable of resisting ageing due to ozone. In order to prove this, the components are exposed to air with high ozone concentration.
Temperature cycle test: the purpose of the test is to provide evidence that the hydrogen components are capable of resisting high variations of temperature. In order to prove this, the hydrogen components are submitted to a temperature cycle of specified duration from the minimum operating temperature up to the maximum operating temperature.
Pressure cycle test: the purpose of the test is to provide evidence that the hydrogen components are capable of resisting high variations of pressure. In order to prove this, the hydrogen components are submitted to a pressure change from atmospheric pressure to the maximum allowable working pressure (MAWP) and then back to atmospheric pressure within a short period of time.
Hydrogen compatibility test: the purpose of the test is to provide evidence that metallic hydrogen components (i.e. cylinders and valves) are not susceptible to hydrogen embrittlement. In hydrogen components that are subjected to frequent load cycles, conditions that can lead to local fatigue and the initiation and propagation of fatigue cracks in the structure must be avoided.
Seat leakage test: the purpose of the test is to provide evidence that hydrogen components are free from leakage while installed in the hydrogen system.
Seamless metallic container
Hoop wrapped container with a seamless metallic liner
Fully wrapped container with a seamless or welded metallic liner
Fully wrapped container with a non-metallic liner.
Burst test: the purpose of the test is to provide the value of the pressure at which the container bursts. In order to prove this, the container is pressurised to a given value, which must be higher than the nominal working pressure of the container. The burst pressure of the container must exceed a specified pressure. The burst pressure of the container must be recorded and be kept by the manufacturer throughout the service life of the container.
Ambient temperature pressure cycle test: the purpose of the test is to provide evidence that the hydrogen container is capable of resisting high variations of pressure. In order to prove this, pressure cycles are carried out on the container until a failure occurs or until a specified number of cycles is reached by increasing and decreasing the pressure to a specified value. The containers must not fail before reaching a specified number of cycles. The number of cycles to failure, along with the location and description of the failure, must be documented. The manufacturer must keep the results throughout the service life of the container.
Leak before break (LBB) performance test: the purpose of the test is to provide evidence that the hydrogen container fails by leakage before rupture. In order to prove this, pressure cycles are carried out on the container by increasing and decreasing the pressure to a specified value. The containers tested must either fail by leakage or exceed a specified number of test cycles without failure. The number of cycles to failure, along with the location and description of the failure, must be recorded.
Bonfire test: the purpose of the test is to provide evidence that the container with its fire protection system does not burst when tested under specified fire conditions. The container, pressurised to working pressure, must only vent through the pressure relief device and must not rupture.
Penetration test: the purpose of the test is to provide evidence that the container does not rupture when penetrated by a bullet. In order to prove this, the complete container with its protective coating is pressurised and penetrated by a bullet. The container must not rupture.
Chemical exposure test: the purpose of the test is to provide evidence that the container can withstand exposure to specified chemical substances. In order to prove this, the container is exposed to various chemical solutions. The pressure of the container is increased to a given value and a burst test as referred to under point (a) is carried out. The container must achieve a specified burst pressure, which must be recorded.
Composite flaw tolerance test: the purpose of the test is to provide evidence that the hydrogen container is capable of resisting exposure to high pressure. In order to prove this, flaws of specified geometry are cut into the container sidewall and a specified number of pressure cycles carried out. The container must not leak or rupture within a number of cycles, but may fail by leakage during the remaining test cycles. The number of cycles to failure, along with the location and description of the failure, must be recorded.
Accelerated stress rupture test: the purpose of the test is to provide evidence that the hydrogen container is capable of resisting exposure to high pressure and high temperatures at the limit of the allowable operating range for an extended period of time. In order to prove this, the container is exposed for a specified time to specified pressure and temperature conditions, and subsequently undergoes a burst test as referred to under point (a). The container must achieve a specified burst pressure.
Extreme temperature pressure cycle test: the purpose of the test is to provide evidence that the hydrogen container can withstand variations of pressure under different temperature conditions. In order to prove this, the container, free of any protective coating, is hydrostatically cycle tested by being subjected to extreme ambient conditions, and subsequently undergoes a burst test and a leak test as referred to under points (a) and (k). When cycle tested, the containers must not show evidence of rupture, leakage or fibre unravelling. The containers must not burst at a specified pressure.
Impact damage test: the purpose of the test is to provide evidence that the hydrogen container remains operational after being submitted to the specified mechanical impacts. In order to prove this, the container is subjected to a drop test, and a specified number of pressure cycles are carried out. The container must not leak or rupture within a specified number of cycles, but may fail by leakage during the remaining test cycles.
Leak test: the purpose of the test is to provide evidence that the hydrogen container does not show evidence of leakage under the specified conditions. In order to prove this, the container is pressurised to its nominal working pressure. It must not show any evidence of leakage detected through cracks, pores or similar defects.
Permeation test: the purpose of the test is to provide evidence that the hydrogen container does not permeate more than a specified rate. In order to prove this, the container is pressurised with hydrogen gas to nominal working pressure and then monitored for permeation in a closed chamber for a specified time under specified temperature conditions.
Boss torque test: the purpose of the test is to provide evidence that the hydrogen container is capable of resisting the specified torque. In order to prove this, a torque is applied to the container from different directions. Then a burst test and a leak test as referred to under points (a) and (k) are carried out. The container must meet the burst and leak test requirements. The applied torque, leakage and burst pressure must be recorded.
Hydrogen gas cycle test: the purpose of the test is to provide evidence that the hydrogen container is capable of resisting high variations of pressure when hydrogen gas is used. In order to prove this, the container is subjected to a number of pressure cycles with the use of hydrogen gas and a leak test as referred to under point (k). Deteriorations, such as fatigue cracking or electrostatic discharge of the container, are inspected. The container must meet leak test requirements. The container must be free of any deterioration, such as fatigue cracking or electrostatic discharge.
Subject to specific requirements for any of the hydrogen components, the test procedures to be applied for the type-approval of hydrogen components, other than containers, designed to use compressed (gaseous) hydrogen must include:
Hydrogen compatibility test set out in point (j) of Annex III.
Ageing test: the purpose of the test is to check whether the non-metallic material used in a hydrogen component can withstand ageing. No visible cracking of the test samples is allowed.
Ozone compatibility test: the purpose of the test is to check whether the elastomer material of a hydrogen component is compatible with ozone exposure. No visible cracking of the test samples is allowed.
It must be isolated from heat sources in the vehicle.
In the case of an internal combustion engine, the container must not be installed in the engine compartment of the vehicle.
It must be adequately protected against all kinds of corrosion.
Metallic components of the hydrogen system must have electrical continuity with the vehicle’s earth.
Directive 2007/46/EC is hereby amended as follows:U.K.
Item | Subject | Regulatory act reference | Official Journal reference | Applicability | |||||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|---|
M1 | M2 | M3 | N1 | N2 | N3 | O1 | O2 | O3 | O4 | ||||
‘62 | Hydrogen system | Regulation (EC) No 79/2009 | L 35, 4.2.2009, p. 32 | X | X | X | X | X | X’ |
Subject | Regulatory act reference | Official Journal reference | M1 | |
---|---|---|---|---|
‘62 | Hydrogen system | Regulation (EC) No 79/2009 | L 35, 4.2.2009, p. 32 | X’ |
Subject | Regulatory act reference (1) | As amended by | Applicable to versions | |
---|---|---|---|---|
‘62. | Hydrogen system | Regulation (EC) No 79/2009’ |
Item | Subject | Regulatory act reference | M1 ≤ 2 500 (1) kg | M1 > 2 500 (1) kg | M2 | M3 |
---|---|---|---|---|---|---|
‘62 | Hydrogen system | Regulation (EC) No 79/2009 | Q | G + Q | G + Q | G + Q’ |
Item | Subject | Regulatory act reference | M1 | M2 | M3 | N1 | N2 | N3 | O1 | O2 | O3 | O4 |
---|---|---|---|---|---|---|---|---|---|---|---|---|
‘62 | Hydrogen system | Regulation (EC) No 79/2009 | A | A | A | A | A | A’ |
Item | Subject | Regulatory act reference | M1 |
---|---|---|---|
‘62 | Hydrogen system | Regulation (EC) No 79/2009 | X’ |
Item | Subject | Regulatory act reference | M2 | M3 | N1 | N2 | N3 | O1 | O2 | O3 | O4 |
---|---|---|---|---|---|---|---|---|---|---|---|
‘62 | Hydrogen system | Regulation (EC) No 79/2009 | Q | Q | Q | Q | Q’ |
Item | Subject | Regulatory act reference | Mobile crane of category N3 |
---|---|---|---|
‘62 | Hydrogen system | Regulation (EC) No 79/2009 | X’ |