2nd International Hydrogen Conference on Hydrogen
Safety.
San Sebastián, Spain – 11.-13. Sept. 2007.
Hydrogen Safety.
New Challenges based on BMW Hydrogen 7.
Christian Müller
Automotive Functional Safety.
Hydrogen Safety
Christian Müller
BMW Group
12.09.2007
Page 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
Hydrogen Safety
Christian Müller
BMW Group
12.09.2007
Page 3
BMW Hydrogen 7.
The Product Development Process.
Technical Goals
Hydrogen 7
Series Development
Qualification for H2
components and systems
First BMW H2 vehicle
provided to users
Hydrogen Safety
Christian Müller
BMW Group
12.09.2007
Page 4
BMW Hydrogen 7.
Hydrogen Technology Features.
LH2-Storage System
Vehicle
LH2 fuel tank system CFK strengthening
in side frame
LH2 coupling system
Hydrogen gas
Control System
warning system
Boil-off-Management
System
New components
Adapted components
H2-Powertrain
Bi-fueled internal
combustion engine
Adapted ignition system
Digital Motor Electronics (DME)
H2 mixture generation system
Hydrogen Safety
Christian Müller
BMW Group
12.09.2007
Page 5
BMW Hydrogen 7.
Hydrogen Protection Measures.
Warning
Fault Control &
Damage Mitigation
Safety functions
Fault-tolerant design
Fault Prevention
High reliability of operation
Hydrogen Safety
Christian Müller
BMW Group
12.09.2007
Page 6
BMW Hydrogen 7 Safety Features.
Gas Warning System with H2 Sensors.
1....... Engine compartment
2....... Passenger compartment
3....... Rear shelf panel
4..... LH2 tank coupling
5..... Barrier concept
A-D: Locking buttons at all doors, which display a flashing red light.
Hydrogen Safety
Christian Müller
BMW Group
12.09.2007
Page 7
BMW Hydrogen 7 Safety Features.
System and Component Tests.
Hydrogen Safety
Christian Müller
BMW Group
12.09.2007
Page 8
BMW Hydrogen 7 Safety Features.
Crash Tests.
FMVSS 301
70% Offset right, 80 km/h
Car-to-Pole at tank coupling
30 km/h
Hydrogen Safety
Christian Müller
BMW Group
12.09.2007
Page 9
BMW Hydrogen 7 Safety Features.
Crash Test Results.
FMVSS 301
70% Offset right, 80 km/h
Result: no leakage from the
H2 system.
Car-to-Pole at tank coupling
30 km/h
Result: no leakage from the
H2 system.
Hydrogen Safety
Christian Müller
BMW Group
12.09.2007
Page 10
BMW Hydrogen 7 Safety Features.
Crash Tests.
Truck override
Barrier height 700 mm
70 km/h (EES 45 km/h)
Hydrogen Safety
Christian Müller
BMW Group
12.09.2007
Page 11
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.
Hydrogen Safety
Christian Müller
BMW Group
12.09.2007
Page 12
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.
Hydrogen Safety
Christian Müller
BMW Group
12.09.2007
Page 13
BMW Hydrogen – New Challenges.
Parking in Enclosed Areas.
Objective:
Unrestricted parking in enclosed areas.
H2 limits to be controlled:
Normal Case
Boil Off
Uncritical amount
< 5 g/h
< 20 g/h
< 200 g/h
Critical amount
> 200 g/h*
B=2,85 m
L=5,8 m
H=2,11 m
*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
Hydrogen Safety
Christian Müller
BMW Group
12.09.2007
Page 14
BMW Hydrogen – New Challenges.
Parking in Enclosed Areas.
Risks
H2-emission
>> 200 g/h
Ignition /explosion
critical H2
while humans are
mixture in room exposed in danger
zone
Safety goal: Prevent severe injury due to emission of critical
quantity of H2 in enclosed areas.
Requirements
Measures
Prevent
emission of
critical H2
quantity
- Vacuum
stability
- Vacuum
monitoring
Prevent
formation of
critical mixture
- Delay H2
emission
- Generate
emergency
call
Evacuate danger
zone in time
Warning (optical,
acoustic, olfactory)
Hydrogen Safety
Christian Müller
BMW Group
12.09.2007
Page 15
BMW Hydrogen – New Challenges.
Parking in Enclosed Areas.
We need to know
Project Topics
how to evaluate and classify
the criticality of H2 air
mixtures in different garage
types, depending on
-
Parameter studies for H2
emission scenarios in
vehicle environment
-
Experimental studies of H2diffusion in enclosed rooms.
- rate and speed of emitted H2
-
total amount of emitted H2
-
position and geometry of H2
outlet
funded
projects* -
Conditions and
consequences of an ignition.
-
Quality criteria for garages.
- garage size and architecture
-
garage ventilation
* HySafe, InsHyde, HyGarage, NIP, …
More detailed, realistic CFD
models for garage types
BMW Hydrogen – New Challenges.
Degrading Concept of a Mono-Fuel Car.
Functional
degradation
Severity of Defects
Hydrogen Safety
Christian Müller
BMW Group
12.09.2007
Page 16
Request for
service /
maintenance
e.g.: replacing
defective sensor
e.g. in case of a
defective sensor
Pre-warned
e.g.: no fueling;
shut-off
reducing engine
power;
no driving in
enclosed areas
e.g. in case of
icing of coolant
heat exchanger
H2 alarm
in double
barrier
Immediate
shut-off
H2 alarm
in
compart
ment
Hydrogen Safety
Christian Müller
BMW Group
12.09.2007
Page 17
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