SAE J 2601-3-2013 Fueling Protocol for Gaseous Hydrogen Powered Industrial Trucks.pdf

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5、d 2013-06 Fueling Protocol for Gaseous Hydrogen Powered Industrial Trucks RATIONALE Currently there is no published standard fueling protocol or method for fueling hydrogen powered industrial trucks (HPITs). HPITs include utility vehicles, fork lifts, tugs and other electric vehicles using H2 Fuel C

6、ell battery replacement modules (BRMs). As the market for these vehicles expands, there is interest in having a standard fueling method for hydrogen powered industrial trucks. FOREWORD The intent of this document is to provide guidance for a performance-oriented dispenser fueling protocol for hydrog

7、en powered industrial trucks. TABLE OF CONTENTS 1. SCOPE 2 2. REFERENCES 3 2.1 Applicable Documents 3 3. DEFINITIONS . 4 3.1 HYDROGEN POWERED INDUSTRIAL TRUCK 4 3.2 CAPACITY 4 3.3 DISPENSER COMPONENTS . 4 3.4 TEMPERATURE . 5 3.5 PRESSURE . 5 3.6 STATE OF CHARGE (SOC) . 6 4. ABBREVIATIONS AND SYMBOLS

8、 7 4.1 Abbreviations . 7 4.2 Symbols . 7 5. GENERAL REQUIREMENTS FOR FUEL SYSTEM AND INTERFACE 7 5.1 Operating Conditions of the Vehicle Fuel System . 7 5.2 Vehicle Storage Systems (VSS) 8 5.3 Fueling Process Limits 8 5.4 Special Requirements of Fleet Operations . 9 5.5 Special Requirements for Fuel

9、ing Light Duty Road Vehicles with HPIT dispensers . 9 SAE J2601-3 Issued JUN2013 Page 2 of 16 6. HPIT DISPENSER CONTROL METHODS. 9 6.1 Fill to Service Pressure . 9 6.2 Fill to Target Pressure with fixed orifice 10 6.3 Fill to Target Pressure with variable Flow Rate . 11 7. HPIT AND BRM FUELING PROCE

10、SS . 11 7.1 Automatic Shut Off Valve (ASOV) . 11 7.2 Integrity Validation . 12 7.3 Initial Integrity Check . 12 7.4 Integrity Check during Fueling Event 12 8. HPIT DISPENSERS OPTIONS . 13 8.1 Communications . 13 8.2 Temperature Feedback from Vehicle Tank. . 13 8.3 Water Removal . 13 8.4 Target Press

11、ure Calculation Methods . 13 8.5 Accommodating hot and cold soak conditions 13 9. FUELING PROCESS QUALIFICATION AND VALIDATION 14 9.1 Verification of Dispenser Performance . 14 9.2 Field Verification Of Fueling Protocol And Dispenser Performance . 14 9.3 Operating Conditions . 15 10. NOTES 16 10.1 M

12、arginal Indicia . 16 1. SCOPE This document establishes safety limits and performance requirements for gaseous hydrogen fuel dispensers used to fuel Hydrogen Powered Industrial Trucks (HPITs). It also describes several example fueling methods for gaseous hydrogen dispensers serving HPIT vehicles. SA

13、E J2601-3 offers performance based fueling methods and provides guidance to fueling system builders as well as suppliers of hydrogen powered industrial trucks and operators of the hydrogen powered vehicle fleet(s). This fueling protocol for HPITs can support a wide range of hydrogen fuel cell hybrid

14、 electric vehicles including fork lifts, tractors, pallet jacks, on and off road utility, and specialty vehicles of all types. The mechanical connector geometry for H25 and H35 connectors are defined in SAE J2600 Compressed Hydrogen Surface Vehicle Refueling Connection Devices. Multiple fueling meth

15、ods are described in this document and include: 1. Fill to Service Pressure with fixed area flow-limiting device 2. Fill to Target Pressure with fixed area flow-limiting device 3. Fill to Target Pressure with variable area flow-limiting device These three dispensing methods are detailed in Section 6

16、 and include a schematic of control components for vehicle fueling. These methods allow for market differentiation with varied target fill pressures relative to 100% SOC. These methods are examples of how dispensers may function but are not intended to limit options for new dispenser technologies or

17、 fueling methods, provided they meet the performance based requirements. This document is suitable for all vehicle tank fueling systems above 18 L water volume and may be used for fueling of all types of Hydrogen Powered Industrial Trucks (HPITs), and Battery Replacement modules (BRMs). The fueling

18、limits shown in Section 5 are harmonized with the fueling assumptions used for on-board fuel systems that comply with CSA HPIT-1. SAE J2601-3 Issued JUN2013 Page 3 of 16 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this specification to the extent specified herein

19、 Unless otherwise indicated, the latest issue of SAE publications shall apply. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org. SAE J2600 Compressed Hydro

20、gen Surface Vehicle Fueling Connection Devices TIR J2601 Fueling Protocols for Light Duty Gaseous Hydrogen Surface Vehicles SAE J2719 Hydrogen Fuel Quality for Fuel Cell Vehicles SAE J2574 Information Report - Fuel Cell Vehicle Terminology SAE J2578 Recommended Practice for General Fuel Cell Vehicle

21、 Safety TIR J2579 Technical Information Report for Fuel Systems in Fuel Cell and Other Hydrogen Fueled Vehicles TIR J2760 Information Report Pressure Terminology Used in Fuel Cells and Other Hydrogen Vehicle Applications 2.1.2 CSA Publications CSA America is currently developing and revising compone

22、nt certification standards applicable to hydrogen filling stations and hydrogen vehicles. Contact CSA America to see if new standards are published and available at CSA America, 8501 East Pleasant Valley Road, Cleveland, OH 44131-5575, Tel: 216-524-4990, www.csa-america.org. CSA CHMC 1 Material Comp

23、atibility for Use in Hydrogen Applications CSA HPIT-1 System Components for Powered Industrial Trucks CSA HGV 4.1 Hydrogen Dispenser CSA HGV 4.2 Hoses CSA HGV 4.3 Fueling Parameters CSA HGV 4.4 Breakaway Devices CSA HGV 4.5 Priority and Sequencing CSA HGV 4.6 Manual Valves for use in Hydrogen Fuelin

24、g Station(s) CSA HGV 4.7 Automatic Valves for use in Hydrogen Fueling Station(s) CSA HGV 4.8 Fueling Station Compressors CSA HGV 4.10 Fittings SAE J2601-3 Issued JUN2013 Page 4 of 16 2.1.3 UL Publications Available from Underwriters Laboratories Inc., 333 Pfingsten Road, Northbrook, IL 60062-2096, T

25、el: 847-272-8800, . UL 2267 Fuel Cell Power Systems for Installation in Industrial Trucks 3. DEFINITIONS 3.1 HYDROGEN POWERED INDUSTRIAL TRUCK 3.1.1 Battery Replacement Module (BRM) A hydrogen powered fuel cell module or hybrid fuel cell/battery power module that provides direct or semi-direct repla

26、cement of battery power sources within powered industrial equipment (fork trucks, tugs, etc.). 3.1.2 Hydrogen Powered Industrial Truck (HPIT) A Powered Industrial Truck (PIT) is a mobile, power-driven vehicle used to carry, push, pull, lift or stack material. 3.1.3 Receptacle Device connected to the

27、 HPIT or BRM that receives the dispenser nozzle and permits transfer of fuel. This may also be referred to as a fueling inlet. 3.2 CAPACITY 3.2.1 Fast Fueling Fast Fueling is defined as filling a vehicle fuel system at a rate exceeding 1.5 grams per second (1 Nm3/min). Fast Fueling covered by this T

28、IR is typically at fueling speeds of between 6 and 10 grams per second. 3.2.2 Storage Capacity Total mass of hydrogen contained within the storage vessels of a battery replacement module or hydrogen powered industrial truck when filled to service pressure at 15C 3.2.3 Slow fueling Slow Fueling is de

29、fined as filling a vehicle fuel system at a rate less than 1.5 grams per second (1 Nm3/min). 3.3 DISPENSER COMPONENTS 3.3.1 Breakaway A device in the fueling hose assembly that will separate if a vehicle drives away while the dispenser nozzle is connected to the vehicle. The intent of the breakaway

30、is to prevent damage to the vehicle, prevent damage to the dispenser, and to minimize the release of hydrogen. 3.3.2 Communication Connector An (optional) connector specified by the HPIT manufacturer to enable data transfer from the HPIT to the dispenser. It may also be used to ground the vehicle pr

31、ior to fueling. SAE J2601-3 Issued JUN2013 Page 5 of 16 3.3.3 Dewatering Connector An (optional) connector specified by the HPIT manufacturer to allow for water removal from the HPIT as part of the fueling process. 3.3.4 Dispenser The equipment that controls each fueling event; a transfer of hydroge

32、n fuel from the station storage systems to HPIT vehicle storage for the purpose of fueling the vehicle. 3.3.5 Hydrogen Supply System The equipment required to store, condition and transfer hydrogen to the dispensing system for the purpose of fueling HPITs. 3.3.6 Nozzle Device connected to the dispen

33、ser which engages a receptacle on the HPIT or BRM and permits transfer of fuel. 3.4 TEMPERATURE 3.4.1 Ambient Temperature The ground-level temperature of the air measured at the fueling station, not in direct sunlight. 3.4.2 Bulk Hydrogen Temperature The mass-average temperature of the hydrogen gas

34、in the vehicle fuel tank. 3.4.3 Calculated Temperature of Vehicle Storage Tank The temperature of vehicle storage tank during fueling estimated by the dispenser system. 3.4.4 Fuel Delivery Temperature The temperature of the hydrogen gas measured as immediately upstream of the dispenser hose breakawa

35、y as practical. 3.4.5 Vehicle Tank Gas Temperature The gas temperature as measured within the Vehicle Tank. It is assumed to be the average temperature of the gas in the vehicle tank. 3.5 PRESSURE 3.5.1 Compensated Fill Pressure The calculated, temperature-adjusted fill pressure at which fueling sho

36、uld cease such that the settled pressure at 15 C does not exceed the nominal working pressure. 3.5.2 Initial Tank Pressure The vehicle tank gas pressure as measured by the dispenser at the start of the fill. 3.5.3 Integrity Check A pressure hold test of the dispenser over a period of at least 5 s. S

37、AE J2601-3 Issued JUN2013 Page 6 of 16 3.5.4 Maximum Allowable Working Pressure (MAWP) The MAWP is the maximum gauge pressure of the working fluid (gas or liquid) to which a piece of process equipment or system is rated with consideration for initiating fault management above normal operation. 3.5.5

38、 Maximum Vehicle Pressure Drop A pressure drop of 5 MPa as measured station pressure of 20 MPa, a fuel temperature of 15 C and fuel flowing to the vehicle at 10 grams per second. 3.5.6 Overpressure Protection System (OPS) The OPS shall prevent the supply pressure to the dispenser output from reachin

39、g a pressure greater than 1.38 times the Service Pressure. 3.5.7 Pressure Safety Valve (PSV) Pressure activated pressure relief valve To protect the dispenser fill line and vehicle tank from any upset overpressure condition. Set at not more than 1.38 x SP, when there is a source of hydrogen pressure

40、 that is greater than 1.38 times the Service Pressure 3.5.8 Nominal Working Pressure The NWP is the gauge pressure that characterizes typical operation of a pressure vessel, container, or system. For compressed hydrogen gas containers, NWP is the container pressure, as specified by the manufacturer,

41、 at a uniform gas temperature of 15 C (59 F) and 100% SOC. NOTE: NWP is also called Service Pressure. 3.5.9 Vehicle Tank Pressure Pressure of hydrogen gas within a vehicle storage tank. 3.5.10 Target Fill Pressure The calculated pressure at which the dispenser will stop the fueling event. 3.5.11 Ser

42、vice Pressure Service Pressure is synonymous with Nominal Working Pressure. For example, a H35 dispenser has a nozzle rated for 350 bar Service Pressure 3.5.12 Settled Pressure Pressure of hydrogen gas within a vehicle storage tank with gas temperature equilibrated at ambient temperature. A full tan

43、k is at NWP when equilibrated at 15 C. 3.5.13 Pressure Class SAE and NIST designations for hydrogen fueling pressure classes include H25, H35, H50, and H70. 3.6 STATE OF CHARGE (SOC) Ratio of hydrogen density within the vehicle storage system to the full-fill density. SOC is expressed as a percentag

44、e and is computed based on the gas density as per formula below. Note: P and T are the pressure and temperature of the gas inside the vehicle tank, and is the calculated density SAE J2601-3 Issued JUN2013 Page 7 of 16 3.6.1 A standardized equation to calculate hydrogen gas densities is the National

45、Institute of Standards of Technology (NIST) 113,341-350 (2008) with 0.01% accuracy for pressures up to 70MPa http:/nvlpubs.nist.gov/nistpubs/jres/113/6/V113.N06.A05.pdf. 100% SOC=Density Reference Values at 15C and the NWP of the hydrogen storage system 3.6.1.1 H25: Density of H2 at 15C and 25 MPa =

46、 18.14 g/L 3.6.1.2 H35: Density of H2 at 15C and 35 MPa = 24.0 g/L 4. ABBREVIATIONS AND SYMBOLS 4.1 Abbreviations ASOV Automatic Shutoff Valve BRM Battery Replacement Module DCS Dispenser Control System FLD Flow Limiting Device H25 H25 pressure class H2 fueling features a 25 MPa Nominal Working Pres

47、sure H35 H35 pressure class H2 fueling features a 35 MPa Nominal Working Pressure H2 Hydrogen HSS Hydrogen Storage System (on board vehicle) HPIT Hydrogen Powered Industrial Truck MAWP Maximum Allowable Working Pressure NWP Nominal Working Pressure PRD Pressure Relief Device PS Pressure Sensor PSV P

48、ressure Safety Valve OPS Overpressure Protection System SAE Society of Automotive Engineers SP Service Pressure SOC State of Charge VSS Vehicle Storage System 4.2 Symbols (P,T) Gas density, a function of pressure, P, and temperature, T P0 Initial VSS pressure level prior to fueling Ptarget Fueling t

49、arget pressure tfueling Fueling time Pstation Station measurement of pressure at dispenser nozzle dP Pressure drop between dispenser measured pressure and actual tank pressure Pstation Uncertainty in station measurement of pressure at dispenser nozzle Tvehicle VSS temperature data received by station from vehicle during communication fueling SOCstation SOC calculated by station dispenser using P