UL SUBJECT 2262A-2011 OUTLINE OF INVESTIGATION FOR BOROHYDRIDE FUEL CARTRIDGES WITH INTEGRAL FUEL PROCESSING FOR USE WITH PORTABLE FUEL CELL POWER SYSTEMS OR SIMILAR EQUIPMENT (Iss.pdf

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1、UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULDecember 20, 20111UL 2262AOUTLINE OF INVESTIGATIONFORBOROHYDRIDE FUEL CARTRIDGES WITH INTEGRAL FUEL PROCESSINGFOR USE WITH PORTABLE FUEL CELL POWER SYSTEMS OR SIMILAREQUIPMENTIssue Number: 2DECEM

2、BER 20, 2011Summary of TopicsThis is the second issue of the Outline of Investigation for BorohydrideFuel Cartridges with Internal Fuel Processing For Use With Portable FuelCell Power Systems or Similar Equipment.COPYRIGHT 2011 UNDERWRITERS LABORATORIES INC.UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR

3、 FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULDECEMBER 20, 2011UL 2262A2No Text on This PageUL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULCONTENTSINTRODUCTION1 Scope .52 Units of Measurement .53 References .54 Glossary .6CON

4、STRUCTION5 General 76 Corrosive, Toxic and Flammable Material Containing Parts 77 Hazard Analysis 8PERFORMANCE8 Test Considerations .98.1 General .98.2 Samples for Testing 98.3 Determining impermissible limits 109 Material Tests .119.1 Aging of elastomeric gaskets and seals 119.2 Immersion tests .12

5、10 Abnormal Operation Tests - Protection Parameters .1311 Fuel Connection Tests 1311.1 High temperature connection 1311.2 System fuel/cartridge interface connection cycling 1411.3 Cartridge connector cycling 1512 Mechanical Tests .1512.1 General .1512.2 Drop 1612.3 Vibration 1612.4 Crush .1712.5 Pre

6、ssure strength test 1712.6 Mold stress test 1813 Environmental Tests 1813.1 General .1813.2 Temperature cycling 1813.3 Elevated temperature exposure 1913.4 Long-term storage 1913.5 Low Pressure Exposure .2014 Pressure Relief Device Test, Start-to-Discharge 20MANUFACTURING AND PRODUCTION TESTS15 Test

7、s 2015.1 General .2015.2 Pressure 2115.3 Drop 2115.4 Immersion .2115.5 Start-to-Discharge 21DECEMBER 20, 2011 UL 2262A 3UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULMARKINGS AND INSTRUCTIONS16 General 2117 Markings .2218 Instructions 2218.1

8、 General instructions 2218.2 Installation and operating instructions .2318.3 User maintenance instructions .2318.4 Safety instructions 23APPENDIX AStandards for ComponentsA1DECEMBER 20, 2011UL 2262A4UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FRO

9、M ULINTRODUCTION1 Scope1.1 These requirements cover disposable borohydride compound fuel cartridges with integral fuelprocessing for use with portable fuel cell power systems or similar equipment that use gaseous hydrogenfrom the cartridge. The fuel contained within the cartridge consists of a sodiu

10、m or potassium borohydrideformulation, or a mixture of these formulations, which have been shown to be UN Class 8 (Corrosive)materials. The compounds, in liquid state are processed through a chemical reaction within the cartridgethat results in hydrogen gas (for use as a fuel) and borate solution (w

11、aste material stored in the cartridgeuntil disposal).1.2 These requirements also cover cartridges that contain fuel consisting of UN Class 4, Division 4.3(Water Reactive) borohydride compounds. The compounds, in solid state, are processed with the additionof water resulting in a chemical process tha

12、t results in hydrogen gas (for use as fuel) and borate solution(waste material stored in the cartridge until disposal).1.3 These requirements cover cartridges for use in portable fuel cells systems, but do not cover cartridgesfor use in equipment intended to be brought on board passenger aircraft.1.

13、4 The fuel cell cartridges covered by these requirements are for use in ambient temperatures that donot exceed 50C (121F) and whose internal pressures do not exceed 100 psig.1.5 Federal regulatory requirements pertaining to the shipment of fuel cartridges are outside the scope ofthis Outline of Inve

14、stigation.2 Units of Measurement2.1 Values stated without parentheses are the requirement. Values in parentheses are explanatory orapproximate information.3 References3.1 Any undated reference to a code or standard appearing in the requirements of this Outline ofInvestigation shall be interpreted as

15、 referring to the latest edition of that code or standard.DECEMBER 20, 2011 UL 2262A 5UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL4 Glossary4.1 For the purpose of these requirements, the following definitions apply.4.2 CATALYST A substance

16、s such as a metal salt or acid that facilitates the production of hydrogenfrom the borohydride fuel.4.3 CLASS 8 (CORROSIVE) Materials classified in accordance with the UN Recommendations onthe Transport of Dangerous Goods Model Regulations as Class 8.4.4 CLASS 4, DIVISION 4.3 (WATER REACTIVE) Materi

17、als which when exposed to water result inproduction of flammable gases are classified in accordance with the UN Recommendations on theTransport of Dangerous Goods Model Regulations as Class 4, Division 4.3.4.5 FUEL Any solution of sodium or other borohydride compounds with water and/or other specifi

18、edadditives, which is used to produce hydrogen through a chemical reaction between the borohydridecompounds and water.4.6 FUEL (CLASS 4, DIVISION 4.3) Solid borohydride compounds that with the addition of waterand other additives are used to produce hydrogen through a chemical reaction between the b

19、orohydridecompounds and water4.7 FUEL BY-PRODUCTS Consists of borate solutions resulting from the production of gaseoushydrogen within the cartridge.4.8 FUEL COMPONENTS Various separate materials that the fuel is comprised of including solidborohydride compounds, water and additives.4.9 FUEL PROCESS

20、ING CHAMBER Chamber within fuel cartridge that contains the catalyst andwhere the chemical reaction that results in the production of hydrogen takes place.4.10 IMPERMISSIBLE LIMITS:IMPERMISSIBLE LEAKAGE OF FUEL A release of fuel, fuel components, fuel by-productsfrom the fuel cartridge that is visib

21、le and accessible.IMPERMISSIBLE LEAKAGE OF HYDROGEN GAS An unintended release of hydrogen gasfrom its containment system in the fuel cartridge that can result in a hydrogen concentrationgreater than 25% LFL. See 8.3.4.11 RUPTURE A tearing or breaking apart of an object due to a buildup of pressure,

22、an impact, orother force or mechanism applied to the object.4.12 TOOL A screwdriver, coin, key, or any other object that is usable to operate a screw, latch, orsimilar fastening means.4.13 VALVE Component that controls the movement of hydrogen, fuel or fuel components.DECEMBER 20, 2011UL 2262A6UL CO

23、PYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULCONSTRUCTION5 General5.1 Features of the product intended to limit the exposure of fuel and fuel components to users or inhibitthe amount of fuel, or fuel components that can be leaked under normal an

24、d abnormal conditions shall bejudged based on the design and corroborating evidence in the form of valid calculations, technicalreferences and internal test data when determining the products compliance to this Outline ofInvestigation.6 Corrosive, Toxic and Flammable Material Containing Parts6.1 Cor

25、rosive, toxic and flammable materials shall be kept within a closed containment system. The fuelcartridge shall be designed to prevent contact with fuel during fuel cartridge storage, when handling andduring use. Polymeric structural or functional parts of the fuel cartridge (i.e. cartridge housing,

26、 polymericinterlock or guarding devices, valve bodies, etc.) shall have a minimum flame rating of HB as outlined inthe Standard for Tests for Flammability of Plastic Materials for Parts in Devices and Appliances, UL 94.6.2 Parts in contact with the fuel, fuel components, and fuel by-products shall b

27、e resistant to deteriorationfrom those materials as determined by the applicable tests of Section 9.2 (non-metallic) or 13.2 (metallic).Metallic and non-metallic parts in contact with gaseous hydrogen shall be suitable for hydrogen use.Guidance can be found in Basic Considerations for the Safety of

28、Hydrogen Systems, ISO/TR 15916.Non-metallic parts in contact with gaseous hydrogen, fuel or fuel components shall be suitable for theanticipated temperatures they encounter during use as determine by evaluation of the documentation ofthe materials and through the applicable elevated temperature test

29、s of Sections 11 and 13. Elastomericparts shall additionally be evaluated in accordance with 9.1.6.3 Toxic, corrosive and flammable materials and liquid containing parts and their connections shall haveadequate strength to withstand pressures that they are exposed to. Compliance is determined by the

30、differential pressure tests of 12.6.4 Connections between the fuel cartridges and applicable system and within the fuel cartridge itselfshall be sufficiently leak tight as determined by the applicable tests of 11 13.6.5 A filled fuel cartridge shall include provisions for any necessary expansion of

31、fuel due to ambienttemperature or pressure variations. Compliance is determined by the tests of Section 13.6.6 There shall be no fuel and fuel components leakage during connection and disconnection or duringactivation of the fuel cartridge. Cartridges shall be designed to prevent misalignment that w

32、ould result inleakage of impermissible limits as defined in 4.10 during installation and removal of the fuel cartridge.6.7 The fuel cartridge shall be designed for installation without the use of tools. The design of the fuelcartridge or the combination fuel cartridge and end use fuel cell applicati

33、on shall include features toprevent the inadvertent disconnection of the fuel cartridge during use.6.8 The fuel cartridge shall be designed to reduce the risk of impermissible leakage of fuel during travel,normal storage, handling and when installed in the fuel cell power unit and when removed from

34、the fuelcell power unit for disposal. Compliance shall be determined by the tests in this Outline.DECEMBER 20, 2011 UL 2262A 7UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL6.9 The fuel cartridge shall be designed to prevent the uncontrolled

35、mixing of fuel components duringtransportation, storage and use. The fuel cartridge shall be designed to prevent mixing of components thatcould result in a hazardous condition (i.e. hazardous heat build up, flammable or poisonous gas or vapordevelopment not anticipated in the normal operation of the

36、 product). When components are present thatcould mix and form a hazardous condition the combination fuel cartridge and end use fuel cell applicationshall provide at least two independent means to prevent uncontrolled mixing of these components.Examples of these means include but are not limited to:

37、positive activation by the control system; physicalremoval of an impermeable barrier preventing contact; opening of a normally closed manually controlledvalve preventing contact. For at least one of these means for preventing uncontrolled mixing, it shall benecessary for the user to take positive ac

38、tion to remove or deactivate it prior to use. At least one meansfor preventing uncontrolled mixing of these materials shall be provided during use and storage after use.This means may include active control by system electronics, subject to the FMEA analysis of 7.1.6.10 The fuel cartridge design sha

39、ll reasonably prevent the entry of debris that may be present during thestorage and usage of the fuel cartridge.6.11 Accessible valves shall not inadvertently actuate during user handling that would result in fuelleakage. Compliance shall be determined in accordance with the Standard for Protection

40、of Persons andEquipment by Enclosures - Probes for Verification, IEC 61032, and a force of 9.8 N, using test probe 2.Note: Test Probe 2 is referred to as the IEC articulate finger.6.12 Pressure relief valves and rupture discs shall be constructed and marked in accordance with theASME Boiler and allo

41、wed to stabilize for a maximum of 30 minutes, to preventfalse bubble readings from non-leak sources. After the 30 minute stabilization period, the cartridge shallremain immersed for an additional 30 minutes to check for bubbles. There shall be no sign of bubbles asa result of leaks in the cartridge

42、during the 30 minute check period.9 Material Tests9.1 Aging of elastomeric gaskets and seals9.1.1 Three samples of each elastomeric gasket or seal relied upon as a seal against impermissibleleakage and emissions shall be subjected to the Accelerated Aging test of the Standard for Gaskets andSeals, U

43、L 157. As a result of the test, there shall be no cracking or other visible evidence of deterioration.9.1.2 Testing may be conducted in accordance with ISO 188, Rubber, Vulcanized or Thermoplastic -Accelerated Ageing and Heat Resistance Tests.DECEMBER 20, 2011 UL 2262A 11UL COPYRIGHTED MATERIAL NOT

44、AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL9.2 Immersion tests9.2.1 Polymeric parts9.2.1.1 Three samples each of polymeric parts in contact with fuel, or fuel components, shall be subjectedto an immersion test in accordance with 9.2.1.2 9.2.1.4.9.2.1.2 There shall b

45、e no evidence of warpage, cracking, or other signs of deterioration following theimmersion tests. There shall be no dimensional change to the samples greater than 2 percent of theas-received dimensions as a result of the immersion.9.2.1.3 Prior to the immersion conditioning described in 9.2.1.4, the

46、 dimensions (length and diameter orthickness of each sample) are to be determined with appropriate measuring instruments. Immediatelyfollowing the immersion conditioning and after drying in air for 70 1.2hat232C (73 3.6F), thedimensions of each sample shall be measured. The percentage change in dime

47、nsions is to be calculatedas specified in the following equation for each of the three samples and averaged.(Mb-Ma) 100/Mbin which:Mb is the dimension of the sample before the immersion conditioningMa is the dimension of the sample after the immersion conditioningNote: Samples may be rinsed after th

48、e immersion to remove visible residue that may affect the test resultsif necessary prior to drying in air.9.2.1.4 The three samples shall be immersed (completely submerged) in a closed container with the testfluid for 168 h at 23 + 2C (73.4 + 3.6F). The test fluid shall consist of the test fluid (re

49、presentative of thefuel and fuel byproducts in the appropriate concentration) the materials are in contact with in the end useapplication.Note: Container may be vented to release gases during the test.9.2.1.5 Testing may be conducted in accordance with ISO 175, Plastics Methods of test for thedetermination of the effects of immersion in liquid chemicals as an alternative to the methods outlined in9.2.1.1 9.2.1.4.DECEMBER 20, 2011UL 2262A12UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSIO