Guidelines-H2-Fuel-in-CMVs-Nov2007.pdf

GUIDELINES FOR USE OF HYDROGEN

FUEL IN COMMERCIAL VEHICLES

Final Report

November 2007

FOREWORD

This document is intended to be a safety reference for commercial vehicle fleet owners and

operators that use vehicles or auxiliary power units powered by hydrogen. It was designed to

provide commercial vehicle owners and operators with a basic understanding of the properties

and characteristics of hydrogen, descriptions of the types of systems that might use hydrogen

fuel on commercial vehicles, and practical guidelines for the safe use of hydrogen, both on

vehicles and in vehicle maintenance and storage facilities.

Hydrogen properties and characteristics are significantly different from those of other

commercial motor fuels, such as gasoline and diesel fuel, and commercial vehicle systems that

use hydrogen fuel can also be significantly different from typical gasoline or diesel engines. An

understanding of these differences is important to understanding what the operator of a vehicle

NOTICE

This document is disseminated under the sponsorship of the Department of Transportation in the

interest of information exchange. The United States Government assumes no liability for its

contents or the use thereof.

The contents do not necessarily reflect the official policy of the Department of Transportation.

This report does not constitute a standard, specification, or regulation.

The United States Government does not endorse products or manufacturers. Trade or

manufacturers’ names appear herein only because they are considered essential to the objective

of this document.

Technical Report Documentation Page (Form 1700.7)

1. Report No.

FMCSA-RRT-07-020

2. Government Accession No.

3. Recipient's Catalog No.

4. Title and Subtitle:

Guidelines for Use of Hydrogen Fuel in Commercial Vehicles

5. Report Date: November 2007

6. Performing Organization Code

7. Author(s):

John M. Simon, CSP, Booz Allen Hamilton Inc.

Stephen Brady, Booz Allen Hamilton Inc.

Dana Lowell, M. J. Bradley & Associates

Michael Quant, Booz Allen Hamilton Inc.

8. Performing Organization Report No.

9. Performing Organization Name and Address:

Booz Allen Hamilton Inc.

444 S. Flower Street, Suite 1850

Los Angeles, California 90071

10. Work Unit No. (TRAIS)

11. Contract or Grant No.

GS-23F-0025K

12. Sponsoring Agency Name and Address:

U.S. Department of Transportation

Federal Motor Carrier Safety Administration

Technology Division (MC-RRT)

1200 New Jersey Ave. SE

Washington, DC 20590

13. Type of Report and Period Covered

Final Report

14. Sponsoring Agency Code

FMCSA

15. Supplementary Notes:

16. Abstract:

Over the next 50 years, hydrogen use is expected to grow dramatically as an automotive and electrical power source

fuel. As hydrogen becomes commercially viable, the safety concerns associated with hydrogen systems, equipment,

and operation are of concern to the commercial motor vehicle industry. This report is intended to provide guidelines

for use of hydrogen fuel as an alternative fuel by a commercial vehicle fleet operator to ensure long-term safe

operation.

17. Key Words:

alternative fuel, APU, auxiliary power units, buses, commercial vehicles,

compressed fuel cell, guidelines, hydrogen, hydrogen gas, hydrogen injection

system, hydrogen internal combustion engine, hydrogen safety, liquefied

hydrogen, motorcoaches, trucks

18. Distribution Statement

No restrictions.

19. Security Classif. (of this report)

Unclassified

20. Security Classif. (of this page)

Unclassified

21. No. of Pages:

22. Price

Form DOT F 1700.7 (8-72) Reproduction of completed page authorized.

SI* (MODERN METRIC) CONVERSION FACTORS

A PPROXIMATE C ONVERSIONS T O SI U NITS

A PPROXIMATE C ONVERSIONS FROM SI U NITS

Symbol

When You Know

Multiply By

To Find

Symbol

When You Know

Multiply By

To Find

Symbol

LENGTH

Inches

25.4

millimeters

0.039

inches

Feet

0.305

meters

3.28

feet

Yards

0.914

meters

1.09

Yards

Miles

1.61

kilometers

0.621

miles

AREA

in 2

mm 2

in 2

square inches

645.2

square millimeters

0.0016

square inches

ft 2

m 2

ft 2

square feet

0.093

square meters

10.764

square feet

yd 2

m 2

yd 2

square yards

0.836

square meters

1.195

square yards

Acres

0.405

hectares

2.47

acres

mi 2

km 2

mi 2

square miles

2.59

square kilometers

0.386

square miles

VOLUME

fl oz

fluid ounces

29.57

milliliters

0.034

fluid ounces

fl oz

gal

Gallons

3.785

liters

0.264

gallons

gal

ft 3

m 3

ft 3

cubic feet

0.028

cubic meters

35.71

cubic feet

yd 3

m 3

yd 3

cubic yards

0.765

cubic meters

1.307

cubic yards

MASS

Ounces

28.35

grams

0.035

ounces

Pounds

0.454

kilograms

2.202

pounds

short tons (2000 lbs)

0.907

megagrams

1.103

short tons (2000 lbs)

TE MPERATURE (ex act)

T EMPERATURE (exact)

°F

Fahrenheit

5(F-32)/9

Celsius

°C

Celsius

1.8 C + 32

Fahrenheit

°F

Temperature

or (F-32)/1.8

temperature

ILLUMINATION

foot-candles

10.76

lux

Lux

0.0929

foot-candles

foot-Lamberts

3.426

candela/m2

cd/m2

candela/m2

0.2919

foot-Lamberts

FORCE a nd PRESSURE or STRESS

FORC E and PRESSURE or STR ESS

lbf

pound-force

4.45

newtons

0.225

pound-force

lbf

pound-force

per square inch

pound-force

per square inch

psi

6.89

kilopascals

kPa

kilopascals

0.145

psi

* SI is the symbol for the International System of Units. Appropriate rounding should be made to comply with Section 4 of ASTM E380.

ACKNOWLEDGEMENTS

This document was prepared by Booz Allen Hamilton Inc. and M.J. Bradley & Associates, Inc.,

under contract GS-23F-0025K with the Federal Motor Carrier Safety Administration (FMCSA),

a subdivision of the U.S. Department of Transportation (DOT). The FMCSA project manager for

this project was Mr. Quon Kwan, the Booz Allen Hamilton project manager was Mr. John

Simon, and the principal author of this document was Mr. Dana Lowell of M.J. Bradley &

Associates.

The authors are grateful to Mr. Paul Scott, ISE Corporation; Mr. Chris Morgan and Mr. Michael

Chafee, California Highway Patrol; and Mr. Craig Michels, Alameda-Contra Costa Transit

District for providing extensive peer review comments.

The authors would like to thank Mr. William Chernicoff of the DOT Research and Innovative

Technology Administration for lending his expertise to help guide the project, and Mr. Bill

Parsley of Quest Consulting Group for his help with technical editing. The authors would also

like to thank the following organizations and individuals for hosting project team members and

providing background information and valuable insights: the U.S. Environmental Protection

Agency, Mr. Dennis Johnson; The California Fuel Cell Partnership, Mr. Adam Gromis, Ms.

Jennifer Hamilton, Mr. Matthew Forrest, and Ms. Andrea Labue; the California Highway Patrol,

Mr. Chris Morgan and Mr. Mike Chafee; the Santa Clara Valley Transportation Authority, Mr.

Arthur Douwes; the Alameda Contra-Costa Transit District, Mr. Jaime Levin, Mr. Bob Bithell,

Ms. Mallory Nestor-Brush, and Mr. Doug Byrne; ISE Corporation, Dr. Paul Scott, Mr. Jayson

Cannon; UTC Power, Mr. Matthew Riley; Sunline Transit Agency, Mr. Tommy Edwards, Mr.

Frank Shardy and Mr. Polo Del Toro; Daimler Chrysler Research & Technology North America,

Mr. Joe Impullitti; and United Parcel Service, Mr. Jim Breeher and Mr. Adam Spitz, and Delphi,

Mr. Steve Shafer.

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