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Refueling Protocol

Safety and Efficiency in Refueling Hydrogen-Powered Vehicles

Hydrogen stations with gaseous hydrogen play a crucial role in providing H2 fuel for hydrogen-powered vehicles. The refueling process at such stations follows a specific procedure to ensure safe and efficient refueling. This is an automated process referred to as the refueling algorithm in the AFID. Its purpose is to ensure the secure refueling of vehicles within the boundaries of the refueling protocol for high-pressure hydrogen storage systems in vehicles.

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Hydrogen Refueling Stations

Standards for Safe Refueling

During refueling with gaseous hydrogen, in simplified terms, the hydrogen is first transferred from the H2 storage unit to the refueling hose at the station. This step can be achieved through a combination of compression and cooling to bring the hydrogen to the required pressure level. Subsequently, the pressure in the vehicle tank is regulated to enable safe refueling.

A refueling protocol for hydrogen stations is of great importance. It serves as a standard that sets forth the requirements for a safe refueling process. The protocol specifies, for example, how the connection between the vehicle tank and the station is established and which safety measures need to be checked, such as ambient temperature, pressure level, and volume level in the vehicle tank, among others.

The refueling protocol serves several functions. Firstly, it ensures that hydrogen is transferred correctly and safely, minimizing potential risks such as leaks or accidents. It also defines the communication standards between the vehicle and the station to enable effective and reliable refueling. Additionally, the refueling protocol may include information regarding billing and the operation of the station.

Overall, the refueling protocol of hydrogen stations ensures a standardized and safe refueling process. It is a crucial tool for promoting the acceptance and expansion of the hydrogen infrastructure, as well as ensuring reliable refueling for hydrogen-powered vehicles.

Protocols

ISO Refueling Protocols

There are already established refueling protocols according to ISO 19880-1 for passenger cars and light-duty vehicles. Currently, an HD (Heavy-Duty) refueling protocol is being developed within ISO, drawing on the groundwork laid by the PHYRDE project. The refueling of HD applications with 350 bar and 700 bar using high flow rates (over 120g/sec. H2 and 360g/sec. H2) is being addressed in ISO/TC 197 WG 24. In this context, the ISO series ISO 19885-1, ISO 19885-2, and ISO 19885-3 are being developed.

The ISO series ISO 19885-1, ISO 19885-2, and ISO 19885-3

  • ISO 19885-1 serves as the general definition for the development of an HD (Heavy-Duty) refueling protocol. The current progress status is at 95%.
  • ISO 19885-2 serves as the definition for the communication interface between the vehicle and the hydrogen refueling station (HRS). The current progress status is at 25%.
  • ISO 19885-3 defines the refueling protocol. ISO 19885-3 builds upon ISO 19885-1 and is currently in the draft mode for the specific definitions.
ISO 19885-3

Current status of development

  • ISO/TC 197/WG 24, "Gaseous hydrogen – Fuelling protocols for hydrogen fuelled vehicles," is responsible for the development of the main section of ISO 19885-3.
  • This includes "general requirements" for the vehicle, the refueling station, and the protocol (process).
  • These general requirements need to align with each specific communication tank protocol included in ISO 19885-3 (e.g., PRHYDE, RTR, ANN-MPC, etc.).
  • These requirements also need to align with the non-communication protocol and other standardized refueling protocols (e.g., SAE J2601-5).
  • Without this alignment, there can be a mismatch between the requirements for each of these specific refueling protocols and the general requirements.
  • Furthermore, there can be issues with interoperability, which is explicitly to be avoided according to AFID.
  • Another challenge is that some general requirements may depend on other standards that are still under development (e.g., container geometry in ISO 17268-2).
  • According to Paul Karzel (LifteH2 and Chair of ISO/TC 197 WG24), the technical experts are continuously and enthusiastically engaged in the development of the standard. However, there are currently systemic issues within ISO that are unrelated to the Working Group itself.
ISO 19885-3

Timeline

Status: January 24, 2023

SG3A has extended the schedule for completion to ensure alignment with SG 3B, 3C, 3D, and 3E. SG3A will work to complete as much as possible early in the timeline, but there looks to be considerable coordination and alignment with the other subgroups which is needed.

RCS is the abbreviation for Regulations, Codes and Standards. The goal of standardization is the planned unification of tangible and intangible objects, carried out jointly by interest groups, for the benefit of the general public.

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