GB/T 43691.1-2024 PDF English
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GB/T 43691.1-2024: Fuel cell modules - Part 1: Safety---This is an excerpt. Full copy of true-PDF in English version (including equations, symbols, images, flow-chart, tables, and figures etc.), auto-downloaded/delivered in 9 seconds, can be purchased online: https://www.ChineseStandard.net/PDF.aspx/GBT43691.1-2024
GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 27.070
CCS K 82
Fuel cell modules -- Part 1.Safety
(IEC 62282-2-100.2020, Fuel cell technologies -- Part 2-100.Fuel cell modules
-- Safety, MOD)
Issued on: MARCH 15, 2024
Implemented on: OCTOBER 01, 2024
Issued by. State Administration for Market Regulation;
Standardization Administration of the People's Republic of China.
Table of Contents
Foreword... 3
Introduction... 5
1 Scope... 6
2 Normative references... 7
3 Terms and definitions... 9
4 Requirements... 15
4.1 General security policy... 15
4.2 Design requirements... 16
5 Type test... 23
5.1 General... 23
5.2 Impact and vibration test... 24
5.3 Gas leakage test... 24
5.4 Normal operation test... 27
5.5 Allowable working pressure test... 28
5.6 Cooling system pressure test... 28
5.7 Continuous and short-term electrical power... 29
5.8 Overvoltage test... 29
5.9 Withstand voltage test... 29
5.10 Insulation test... 31
5.11 Pressure differential test... 31
5.12 Gas leakage test (repeated)... 32
5.13 Normal operation (repeated)... 32
5.14 Flammable concentration test... 32
5.15 Abnormal operating conditions test... 33
6 Routine test... 36
6.1 General... 36
6.2 Airtightness test... 36
6.3 Voltage withstand test... 36
7 Labels and instructions... 37
7.1 Nameplate... 37
7.2 Mark... 37
7.3 Warning labels... 37
7.4 Documentation... 37
Annex A (informative) Significant hazards, hazardous situations and incidents
addressed in this document... 43
Annex B (informative) Performance and evaluation test reference information... 46
B.1 Evaluate system leak rate using test gases other than the working gas... 46
B.2 Derivation of the "safety factor" for the allowable working pressure test (5.5)... 50
Bibliography... 53
Fuel cell modules -- Part 1.Safety
1 Scope
This document specifies the safety requirements for the structure, normal and abnormal
operation, and testing of fuel cell modules.
This document applies to fuel cell modules with the following electrolytes.
- Alkaline;
- Polymer electrolytes (including direct methanol fuel cells) 1);
- Phosphoric acid;
- Molten carbonate;
- Solid oxides;
- Saltwater solution.
Fuel cell modules, with or without a casing, are capable of operating under significantly
pressurized or near ambient pressure conditions.
This document pertains to the conditions that can cause harm to individuals and damage
to the exterior of fuel cell modules. It does not involve protection against internal
damage to fuel cell modules, as long as such damage does not pose a hazard to the
exterior of the module.
For the needs of special applications, these requirements have been replaced by other
standards for devices equipped with fuel cell modules.
This document does not involve fuel cells for road vehicles.
This document does not limit or inhibit technological progress. If the electrical
materials or structural forms are different from those described in this document,
inspection and testing shall be carried out according to the required purpose. If
substantially equivalent, it shall be deemed to comply with this document.
The fuel cell module is a component of the final product. Conduct a security assessment
on the final product to meet the security requirements of the terminal application
scenario.
1) Also known as proton exchange membrane fuel cell.
This document only pertains to fuel cell modules with DC output.
This document does not involve the peripheral devices shown in Figure 1.
This document does not involve the storage and transportation of fuel and oxidizer in
fuel cell modules.
2 Normative references
The following referenced documents are indispensable for the application of this
document. For dated references, only the edition cited applies. For undated references,
the latest edition of the referenced document (including any amendments) applies.
GB/T 4208, Degrees of protection provided by enclosure (IP code) (GB/T 4208-
2017, IEC 60529.2013, IDT)
GB/T 5169 (all parts), Fire hazard testing for electric and electronic products [IEC
60695 (all parts)]
GB/T 5169.11-2017, Fire hazard testing for electric and electronic products -- Part
11.Glowing/hot-wire based test methods -- Glow-wire flammability test method for
end-products (GWEPT) (IEC 60695-2-11.2014, IDT)
GB/T 5226.1, Electrical safety of machinery -- Electrical equipment of machines --
Part 1.General requirements (GB/T 5226.1-2019, IEC 60204-1.2016, IDT)
GB/T 16855.1, Safety of machinery -- Safety-related parts of control systems -- Part
1.General principles for design (GB/T16855.1-2018, ISO 13849-1.2015, IDT)
IEC 62040-1, Uninterruptible power systems (UPS) -- Part 1.Safety requirements
NOTE. GB/T 7260.1-××××, Uninterruptible power supply equipment (UPS) -- Part 1.Safety
requirements (IEC 62040-1.2022, IDT)
IEC 62061, Safety of machinery -- Functional safety of safety-related control systems
NOTE. GB 28526-2012, Electrical safety of machinery -- Functional safety of safety-related
electrical, electronic and programmable electronic control systems (IEC 62061.2005, IDT)
IEC 62282-4-101, Fuel cell technologies -- Part 4-101.Fuel cell power systems for
electrically powered industrial trucks -- Safety
NOTE. GB/T 41134.1-2021, Fuel cell power systems for industrial electric trucks - Part 1.
Safety (IEC 62282-4-101.2014, MOD)
IEC 62368-1, Audio/video, information and communication technology equipment -
- Part1.Safety requirements
NOTE. GB 4943.1-2022, Audio/video, information and communication technology equipment
- Part 1.Safety requirements (IEC 62368-1.2018, MOD)
IEC 62477-1.2022, Safety requirements for power electronic converter systems and
equipment -- Part 1.General
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
3.1 fuel cell module
A collection of one or more fuel cell stacks, which may include appropriate additional
components if applicable, for assembly into a power generation device or a vehicle.
NOTE. A fuel cell module consists of the following main components. one or more fuel cell stacks,
piping systems for transporting fuel, oxidizer, and exhaust gas, circuit connections for power
transmission of the fuel cell stack, monitoring and/or control means. In addition, fuel cell modules
also include devices for transporting additional fluids (such as cooling media, inert gases), devices
for detecting normal or abnormal operating conditions, ventilation systems for the casing or pressure
vessel and module, and electronic components required for module operation and power regulation.
[Source. IEC 60050-485.2020, 485-09-03]
3.2 acceptance test
The tests specified in the contract are conducted to demonstrate to the customer that the
product meets its technical specifications.
using a higher safety factor may be limited in design.
NOTE 4.The module manufacturer shall provide at least the following information to the end user.
a) PRD/PRV type used;
b) Setting of PRD/PRV opening pressure;
c) Pressure relief capability;
d) End users should study the effectiveness of module PRD/PRV in the final product.
3.29 stack terminal
bus bar
The output end that supplies electricity from the fuel cell stack to the outside.
[Source. IEC 60050-485.2020, 485-06-08]
4 Requirements
4.1 General security policy
Manufacturers should conduct the following written risk analysis.
a) Identify all reasonably foreseeable hazards, hazardous situations, and hazardous
events within the lifespan of the fuel cell power generation system (see Annex A
for a list of typical hazards).
b) Assess the risks of various hazards based on their likelihood of occurrence and
expected severity.
c) To the extent possible, eliminate or reduce the two factors of risk assessment
(likelihood and severity) to an acceptable level of risk by.
1) The intrinsic safety design of structures and their methods; or
2) Using passive control (such as safety barriers, exhaust valves, thermal cut-off
devices, etc.) to ensure safe energy release without enhazarding the
surrounding environment, or using safety related control functions;
3) For risks that cannot be reduced in 1) and 2), signs, warnings, or professional
training should be provided to personnel working in hazardous areas to master
relevant response measures.
To ensure functional safety, the required severity level, performance level, or control
function level should be determined and designed based on the following requirements.
- IEC 62061 (or GB/T 16855.1) is applicable to applications that comply with GB/T
5226.1;
- IEC 60730-1 or ISO 23550 is applicable to household appliances that comply with
IEC 60335-1, including residential, commercial, and light industry;
- GB/T 20438 (all parts) is for other applications.
Use the following standards to guide the Failure Mode and Effects Analysis (FMEA)
and Fault Tree Analysis methods.
- IEC 60812;
- SAE J1739;
- IEC 61025.
The evaluation should also include the following possible risks.
- Temperature of battery stack or module;
- Battery stack or module and/or battery voltage;
- The pressure of the compressed parts.
If the design involves hazards other than those listed in Annex A, they should be
considered and covered.
4.2 Design requirements
4.2.1 General
The fuel cell module should be designed according to the risk assessment of the fuel
cell module manufacturer. All components should.
a) Adapt to the expected temperature, pressure, flow rate, voltage, and current range
for the intended use;
b) Capable of withstanding the reactions, processes, and other conditions
encountered in the intended use.
For the materials and thickness used in fuel cell modules, accessories, stack wiring
terminals, and integration methods of various components, their structure and operating
characteristics should not undergo significant changes under normal installation and use
conditions within a reasonable lifespan. All components of the fuel cell module should
be able to adapt to the mechanical, chemical, and thermal conditions that end users may
encounter during normal use of the product.
The casing of fuel cell modules should comply with the requirements of GB/T 4208 to
adapt to system applications. The fuel cell module should execute the corresponding IP
code.
4.2.2 Characteristics under normal and abnormal operating conditions
The fuel cell module should be designed to withstand all normal operating conditions
defined in the manufacturer's specifications without damage. Abnormal operating
conditions should be handled according to the provisions of 4.1.
4.2.3 Leakage
Depending on the design, there may be a possibility of flammable gas or liquid leakage
(see 5.3 for testing). The gas leakage rate of fuel cell modules under normal and
abnormal operating conditions should be included in the specification document for the
fuel cell system integrator to determine the minimum ventilation capacity of the
required ventilation system [see 7.4.1r)].
The internal fault mode of the fuel cell stack, "crossover", should be included as one of
the risk assessment contents in section 4.1.According to the results of the risk
assessment, measures should be taken to detect or prevent "fuel crossover" in
accordance with the relevant standards given in 4.1, such as "battery voltage
monitoring", to meet the requirements of functional safety.
If there is no crossover protection in the fuel cell module, the product manual should
specify the safeguarding devices or operating procedures that the system integrator
should provide.
NOTE. The classification of hazardous areas is specified in IEC 60079-10-1.
4.2.4 Pressure application
If the fuel cell module includes airtight and pressurized components, these components
should comply with the safety regulations of the corresponding national standards.
The pressurized operating conditions that may cause external hazards to the module
should be identified (see 4.1), and the information should be communicated to the
system integrator.
NOTE. The following module features are as follows.
- Polymer electrolyte fuel cell (PEFC) module. Pressure is an important design element in the
design of PEFC modules (polymer electrolyte fuel cell stacks). The size, material selection,
and manufacturing specifications of PEFC fuel cell stacks are mainly based on strength,
rigidity, and stability to meet their static, dynamic, and/or other operational requirements. For
example, a design that uses coaxial force to compress hardware leaks before fracture.
- Phosphate fuel cell (PAFC) module. PAFC modules typically operate at atmospheric pressure.
- Molten Carbonate Fuel Cell (MCFC) module. The MCFC module is integrated into the MCFC
power generation system for pressurized operation. The MCFC power generation system
includes the casing of the MCFC module. It is designed according to relevant national and
international specifications and standards for pressure systems. According to the above
regulations, the hazard of MCFC module caused by pressurization can be safeguarded by the
shell.
- Solid oxide fuel cell (SOFC) module. The SOFC module is integrated into the pressurized
operation of the SOFC power generation system. The SOFC power generation system
includes the casing of the SOFC module. It is designed according to the relevant national and
international specifications and standards for pressure systems.
4.2.5 Fire and auto-ignition
4.2.5.1 General
Measures should be taken to protect the fuel cell module, such as ventilation, gas
detectors, controlled oxidation, and operating temperatures above the auto-ignition
temperature, to prevent gas leakage from the fuel cell module or its interior from
reaching explosive concentrations.
If the protective measures are part of the fuel cell module, the safeguarding level should
comply with the requirements of the relevant standards in 4.1.
If the protective measures are not part of the fuel cell module, the fuel cell module
manufacturer should provide design standards for such devices (such as the required
ventilation rate).
Components and materials classified as flammable gas environments should be
constructed or made of flame-retardant materials to prevent external ignition of fuel cell
modules. The combustibility of the material should ensure that it will not continue to
burn after cutting off the power supply, fuel, and oxidant supply. According to the
requirements of GB/T 5169 (all parts), materials that meet V-0, V-1, or V-2 should be
selected and validated. Relevant information in accordance with GB/T 51691.1-2017
should be provided, see 7.4.1aa).
NOTE. The s auto-ignition temperature listed in standards such as ISO/IEC 80079-20-1 [7] is the
lowest temperature at which a combustible gas mixture ignites. The actual auto-ignition temperature
may be much higher than these values. This depends on the surface geometry, material, and actual
gas mixture. The auto-ignition temperature required here refers to the auto-ignition temperature at
which flammable gases can ignite under any conditions based on the selected material and geometric
structure.
The heat resistance and fire resistance requirements of the application standards
described in 4.1 should be considered.
It is the fuel cell system integrator's responsibility to protect these live components to
prevent electric shock.
4.2.11 Insulation materials and dielectric strength
The design of all dielectrics used between live and non-current-carrying metal parts in
fuel cell modules shall comply with the standards given for electrical equipment of the
relevant voltage level in 4.2.8.
For mechanical properties that may affect the functional performance of the material,
such as compressive strength, the design temperature shall be at least 20 K or 5%
(whichever is higher) higher than the maximum temperature under normal operating
conditions, but shall not be lower than 80°C.
The determination shall be based on the properties and characteristics of the material as
specified by the material manufacturer.
4.2.12 Protective earthing/connection
The following provisions apply to situations where there are differences from the
relevant standards mentioned in 4.2.8.
Accessible non-current-carrying metal parts that may become energized due to an
electrical fault and cause electric shock or energy hazards should meet the requirements
of protective earthing or connection to a common point if the system is applicable.
To ensure good electrical contact, the conductors should be protected against corrosion
and designed to prevent loosening and twisting while maintaining contact pressure.
There should be no electrochemical corrosion between metal parts. Based on the
conditions of use, storage and transportation, resistance to electrochemical corrosion
can be achieved through appropriate electroplating or coating processes.
4.2.13 Shock and vibration
The manufacturer's documentation should include the shock and vibration limits that
the fuel cell module is designed to withstand and the corresponding standards.
5 Type test
5.1 General
Use test equipment to simulate the fuel cell system or conduct tests using the fuel cell
system itself to obtain the required operating conditions. Equipment used for normal
operating tests can be used as conditioning equipment for initial startup of the fuel cell
module. The tests should be performed in the following order. Testing under abnormal
conditions may be destructive.
Unless otherwise specified, fuel cell modules should be tested under the following
environmental conditions.
- Altitude not exceeding 1000 m;
- Ambient temperature 5°C~40°C.
5.2 Impact and vibration test
The fuel cell module shall comply with the shock and vibration test limits specified in
the manufacturer's documentation.
NOTE. If the manufacturer does not specify impact and vibration limits, this test need not be
performed.
If the fuel cell module can withstand vibration and shock to the standard specified by
the manufacturer without damage during the test, it meets the requirements. The fuel
cell module is tested after conditioning.
5.3 Gas leakage test
5.3.1 General
This test does not apply to fuel cell module gas leakage in the following situations.
- The operating temperature is higher than the auto-ignition temperature of the
flammable gas (see 4.2.5); or
- The fuel cell is placed in an airtight container that complies with relevant national
standards.
In cases where a full stack cannot be used, a stack with a reduced but still representative
number of cells may be used. Leakage should be calculated based on a ratio of the
number of cells.
Proceed as in 5.3.2 or 5.3.3.
5.3.2 Flow meter method
The fuel cell module should operate at rated current and reach thermal equilibrium at
the maximum operating temperature.
Stop operation after the above conditions are met. Purge the fuel cell module. Close the
gas outlet. Reduce the fuel cell module temperature to or below the specified minimum
operating temperature. Pressurize the fuel cell module with standard anode gas or an
......
Source: Above contents are excerpted from the full-copy PDF -- translated/reviewed by: www.ChineseStandard.net / Wayne Zheng et al.
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