1. 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.

2. 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

3. Hydrogen Safety Christian Müller BMW Group 12.09.2007 Page 3 BMW Hydrogen 7. The Product Development Process. Series Development Qualification for H 2 components and systems First BMW H 2 vehicle provided to users Technical Goals Hydrogen 7

4. Hydrogen Safety Christian Müller BMW Group 12.09.2007 Page 4 BMW Hydrogen 7. Hydrogen Technology Features. LH 2 -Storage SystemVehicleH 2 -Powertrain New components Adapted components Bi-fueled internal combustion engine Adapted ignition system Hydrogen gas warning system CFK strengthening in side frame Control System Boil-off-Management System LH 2 fuel tank system LH 2 coupling system Digital Motor Electronics (DME) H 2 mixture generation system

5. Hydrogen Safety Christian Müller BMW Group 12.09.2007 Page 5 BMW Hydrogen 7. Hydrogen Protection Measures. High reliability of operation Fault-tolerant design Safety functions Warning Fault Prevention Fault Control & Damage Mitigation

6. Hydrogen Safety Christian Müller BMW Group 12.09.2007 Page 6 BMW Hydrogen 7 Safety Features. Gas Warning System with H 2 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.

7. Hydrogen Safety Christian Müller BMW Group 12.09.2007 Page 7 BMW Hydrogen 7 Safety Features. System and Component Tests.

8. 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

9. Hydrogen Safety Christian Müller BMW Group 12.09.2007 Page 9 Car-to-Pole at tank coupling 30 km/h Result: no leakage from the H 2 system. FMVSS 301 70% Offset right, 80 km/h Result: no leakage from the H 2 system. BMW Hydrogen 7 Safety Features. Crash Test Results.

10. 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)

11. 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.

12. 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 H 2 technology - tested for the user.

13. Hydrogen Safety Christian Müller BMW Group 12.09.2007 Page 13 BMW Hydrogen – New Challenges. Parking in Enclosed Areas. *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 H=2,11 m B=2,85 m L=5,8 m Objective: Unrestricted parking in enclosed areas. H2 limits to be controlled: Normal Case< 5 g/h Boil Off< 20 g/h Uncritical amount< 200 g/h Critical amount> 200 g/h*

14. Hydrogen Safety Christian Müller BMW Group 12.09.2007 Page 14 BMW Hydrogen – New Challenges. Parking in Enclosed Areas. Safety goal: Prevent severe injury due to emission of critical quantity of H 2 in enclosed areas. Risks Requirements Measures H 2 -emission >> 200 g/h critical H 2 mixture in room Ignition /explosion while humans are exposed in danger zone Prevent emission of critical H 2 quantity Prevent formation of critical mixture Evacuate danger zone in time -Vacuum stability -Vacuum monitoring -Delay H 2 emission -Generate emergency call Warning (optical, acoustic, olfactory)

15. Hydrogen Safety Christian Müller BMW Group 12.09.2007 Page 15 BMW Hydrogen – New Challenges. Parking in Enclosed Areas. * HySafe, InsHyde, HyGarage, NIP, … Project Topics -Parameter studies for H 2 emission scenarios in vehicle environment -Experimental studies of H 2 - diffusion in enclosed rooms. -More detailed, realistic CFD models for garage types -Conditions and consequences of an ignition. -Quality criteria for garages. funded projects* We need to know how to evaluate and classify the criticality of H 2 air mixtures in different garage types, depending on -rate and speed of emitted H 2 -total amount of emitted H 2 -position and geometry of H 2 outlet -garage size and architecture -garage ventilation

16. Hydrogen Safety Christian Müller BMW Group 12.09.2007 Page 16 BMW Hydrogen – New Challenges. Degrading Concept of a Mono-Fuel Car. Severity of Defects e.g. in case of a defective sensor Request for service / maintenance e.g.: replacing defective sensor e.g. in case of icing of coolant heat exchanger Functional degradation e.g.: no fueling; reducing engine power; no driving in enclosed areas H 2 alarm in double barrier Pre-warned shut-off H 2 alarm in compart ment Immediate shut-off

17. 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 H 2 safety technology - clearly defined constraints for the vehicle environment (public/private garages, fuelling stations, workshops …) - Operationally tested, reliable automotive H 2 components