J3121_202202 Hydrogen Vehicle Crash Test Lab Safety Guidelines

The scope of this document is to provide an overview of the risks and protective precautions to ensure safe and effective testing procedures for the test personnel and the vehicle during the testing of a hydrogen fuel cell vehicle. The main risks associated with a hydrogen fuel cell vehicle are the fuel cell stack, hydrogen storage vessel, fuel cell system components and the high voltage battery. Risks could be summarized from the battery into thermal runaway possibly leading to fire or explosion, electrolyte spillage and electrical shock or electrocution. The hydrogen fuel cell system risks include electrical shock or electrocution and possible release of hydrogen gas (if tested with). Vehicle crash testing protection should be coordinated with the system or component manufacturer(s) suggestions. Precautions should be taken with the handling, transportation, and storage of the vehicle pre-crash and post-crash. This document was written to provide and an understanding of the risks and precautions and should be reviewed periodically to ensure conformance to new technological developments.