Safety Watchdog for universally safe gaseous high pressure hydrogen fillings

Abstract

The fast filling time for hydrogen fuel cell vehicles makes them a user-friendly zero emission alternative to fossil fuel powered vehicles. The filling, by compressing gas into the vehicle tanks, produces heat that can be damaging. There are different protocols, standardized or the intellectual property of station operators, dedicated for different specific applications taking into account the specificity of the vessel and customer requirements. Standard protocols are developed for worst case conditions across a broad range of vehicle tank sizes and configurations. These worst case conditions do not result in the most economical equipment solution for hydrogen fueling. To ensure safety for different existing and future potential protocols a new “Safety Watchdog” approach is suggested in the current paper. This “Safety Watchdog” monitors the fueling process boundary conditions independently from the main process controls. The decoupling between the watchdog and the protocol allows use of protocols that are more economically beneficial while ensuring full safety conditions. The current paper provides a mathematical formulation of the Safety Watchdog as well as its validation versus modeling and field experimental data.