Annexure A

H59 Gas-Flow-Management™ Refuelling Station Overview, Standards Alignment & Risk Assessment for Refuelling Hydrogen Powered Vehicles

Category
ESSNA™ H59™
Standard Reference
Hydrogen Purity
The ESSNA™ H59™ station or ESSNA™’s™ scope of a retrofit strictly adheres to the SAE J-2719 standard, with consistent reliable on-spec Fuel Cell Standard purity of 99.97% and CO < 0.2 ppm. Our system ensures hydrogen meets the quality requirements necessary for fuel cell vehicles. ESSNA™ owns a purification technology that outperforms PSA (pressure swing adsorption) and meets the required fuel cell standards.
SAE J-2719 “Hydrogen Fuel Quality for Fuel Cell Vehicles”; ISO 19880-8 “Gaseous hydrogen Fueling stations — Part 8: Fuel Quality Control”; ISO 14687 “Hydrogen Fuel Quality – Product Specification”
HD Dispensing Capability
The ESSNA™ H59™ station or ESSNA’s™ scope of a retrofit will be designed to meet SAE J2601-2 standard and complies with ISO 19880-1, providing safe and efficient fueling protocols for heavy-duty hydrogen vehicles. The station features HD Dispensing Capability at 700 Bar (H70) and a compression capacity to meet operational objectives. The control parameters relating to fueling such as fueling speed, pre-cooling class, and final pressure are to be determined, ensuring safe hydrogen transfer. The station may support higher flow rates, up to 120 grams per second (g/s), to accommodate the larger fuel requirements of heavy-duty vehicles. The system may be designed to achieve fueling times of less than 20 minutes for larger vehicles with compressed hydrogen storage systems (CHSS) up to 70 kilograms. Compliance with J2601-2 standards for 700 bar (H70) fueling as well as ANSI/CSA-HGV 4.1 (ETL) will be demonstrated through fuel logs. Hot and Cold case scenarios are implemented to guarantee optimal performance under varying environmental conditions, preventing overheating and overfilling during refueling. Included components are confirmed / estimated to be hydrogen compressor and associated hydraulic unit, internal high-pressure storage pack, hydrogen heat exchanger, integrated dispenser, and hydrogen flowmeter.
SAE J2601-2 “Fueling Protocols for Gaseous Hydrogen Powered Heavy Duty Vehicles”; ISO 19880-1 “Gaseous hydrogen Fueling stations — Part 1: General requirements”; ISO 19880-2 “Gaseous Hydrogen—Fuelling stations Part 2: Dispensers and dispensing systems”; ISO 19880-5:2019 “Gaseous hydrogen — Fueling stations — Part 5: Dispenser hoses and hose assemblies”; ANSI/CSA-HGV 4.1 (ETL) “Hydrogen Dispensing Systems”; ANSI/CSA-HGV 4.2 “Hoses for compressed hydrogen fuel stations, dispensers and vehicle fuel systems”; ANSI/CSA-HGV 4.3 “Test Methods for Hydrogen Fueling Parameter Evaluation”
Hydrogen Station Communication, Control Systems, Operational Standards, and Safety
We would deliver the following in designing and building a station (1) implementation of SAE J-2799 communication protocols to ensure 95–100% SOC fueling (state of charge), (2) the presence of a point-of-sale or data-logging system, and (3) design adaptability to various configurations and pressures suitable for medium, heavy and light-duty vehicles. Implementing and installing a main electrical disconnect, nitrogen distribution panel, hydrogen-distribution sequencing instrumentation/valve panels, and safety devices (flame detection, hydrogen gas detection, emergency-stop buttons, and pressure, temperature, and flow monitoring). The station will also have warning red strobe lights and audible horns for abnormal conditions. Additional components include the main electrical power and control enclosure with a dedicated HMI for on-site monitoring and station control, the process PLC and safety system, and a nitrogen distribution panel with automatic switching between primary and secondary nitrogen sources. Added: Functional safety lifecycle per IEC 61508/61511 with SIL assignment for safety instrumented functions (SIFs); hazardous-area electrical compliance per IEC 60079; and a documented compliance program (inspection, testing, maintenance) with audit intervals ≤ 12 months, including HAZOP/FMEA in line with ISO 19880-1 Annex G.
SAE J2799; ISO 17268:2020; SAE J2600; NFPA 2; NBIC; SCA B51:2019; CAN/BNQ 1784-000:2008; AIAA G-095:2004; ASME STP-PT-006:2007; ANSI/NACE TM0284-2016; IEC 61508 / IEC 61511; IEC 60079 Series; ISO 19880-1 Annex G; ISO 9001; ISO 14001
Optional LD Dispensing Capability
ESSNA™ H59™ station or to meet the SAE J2601-1 standard and complies with ISO 19880-1, providing safe and efficient fueling protocols for light-duty hydrogen vehicles. Optional integration.
SAE J2601-1; ISO 19880-1; ISO 19880-2; ISO 19880-5:2019; ANSI/CSA-HGV 4.1; ANSI/CSA-HGV 4.2; ANSI/CSA-HGV 4.3
Functional Safety (SIL/SIS)
Safety instrumented systems shall comply with IEC 61508/61511 lifecycle requirements. SIL targets will be assigned, validated, and verified using quantitative risk assessment; SIF proof-test intervals and diagnostics will be documented.
IEC 61508 / IEC 61511 — Functional Safety Standards
Material Compatibility & Pressure Vessels
Cylinders, piping, and composite storage shall use materials compatible with hydrogen service and embrittlement resistance; fabrication and testing shall comply with ISO 11114, ISO 11120, and ISO 15869.
ISO 11114; ISO 11120; ISO 15869
Explosive Atmospheres (Hazardous Area Electrical)
All electrical/electronic equipment within classified areas shall meet IEC 60079 requirements for selection, installation, and protection methods (e.g., Ex d, Ex e, Ex i).
IEC 60079 Series — Explosive Atmospheres (ATEX)
Transport & Handling Standards
Portable and transportable hydrogen storage systems shall meet ISO 16111 (metal hydride), ADR, and DOT CFR 49 requirements for packaging, relief devices, and safe carriage.
ISO 16111; ADR 2023; DOT CFR 49
Risk Assessment & Continuous Compliance
Perform HAZOP and FMEA per ISO 19880-1 Annex G; maintain a formal inspection, testing, and maintenance program with audit intervals not exceeding 12 months. Maintain quality and environmental controls per ISO 9001 and ISO 14001.
ISO 19880-1 Annex G; ISO 9001; ISO 14001

Hydrogen Purity

ESSNA™ H59™ Specification

The ESSNA™ H59™ station or ESSNA™’s™ scope of a retrofit strictly adheres to SAE J-2719, with consistent reliable on-spec Fuel Cell Standard purity of 99.97% and CO < 0.2 ppm. Our system ensures hydrogen meets the quality requirements for fuel-cell vehicles. ESSNA™ owns purification technology that outperforms PSA (pressure swing adsorption) and meets required fuel-cell standards.

Industry Standard References

SAE J-2719; ISO 19880-8; ISO 14687

Heavy-Duty Dispensing Capability

ESSNA™ H59™ Specification

Designed to meet SAE J2601-2 and ISO 19880-1, providing safe and efficient fueling for heavy-duty hydrogen vehicles. Includes HD dispensing at 700 bar (H70), higher flow rates up to 120 g/s, and fueling times under 20 minutes. CHSS up to 70 kg, J2601-2 compliant logs, hot/cold case scenarios, hydrogen compressor, hydraulic unit, internal HP storage, heat exchanger, integrated dispenser, and flowmeter.

Industry Standard References

SAE J2601-2; ISO 19880-1; ISO 19880-2; ISO 19880-5:2019; ANSI/CSA-HGV 4.1; ANSI/CSA-HGV 4.2; ANSI/CSA-HGV 4.3

Communication, Controls & Safety

ESSNA™ H59™ Specification

Includes SAE J-2799 communication for 95–100% SOC fueling, POS/data-logging, configuration flexibility for multiple vehicle classes, electrical disconnect, nitrogen distribution panel, sequencing valves, safety devices (flame detection, H2 detection, E-stop, pressure/temperature/flow monitoring), alarms, HMI/PLC systems, nitrogen auto-switching, IEC 61508/61511 functional safety lifecycle, SIL assignments, hazardous-area compliance per IEC 60079, and full documented compliance program with ≤12-month audit intervals including HAZOP/FMEA per ISO 19880-1 Annex G.

Industry Standard References

SAE J2799; ISO 17268:2020; SAE J2600; NFPA 2; NBIC; CSA B51:2019; CAN/BNQ 1784-000:2008; AIAA G-095:2004; ASME STP-PT-006:2007; ANSI/NACE TM0284-2016; IEC 61508; IEC 61511; IEC 60079 Series; ISO 19880-1 Annex G; ISO 9001; ISO 14001

Optional Light-Duty Dispensing

ESSNA™ H59™ Specification

Designed to meet SAE J2601-1 and ISO 19880-1, providing safe fueling protocols for light-duty hydrogen vehicles. Optional integration into station design.

Industry Standard References

SAE J2601-1; ISO 19880-1; ISO 19880-2; ISO 19880-5:2019; ANSI/CSA-HGV 4.1; ANSI/CSA-HGV 4.2; ANSI/CSA-HGV 4.3

Functional Safety (SIL/SIS)

ESSNA™ H59™ Specification

Safety instrumented systems shall comply with IEC 61508/61511 lifecycle requirements. SIL targets assigned, validated, and verified using quantitative risk assessment. Proof-test intervals and diagnostics documented.

Industry Standard References

IEC 61508; IEC 61511

Material Compatibility & Pressure Vessels

ESSNA™ H59™ Specification

Cylinders, piping, and composite storage use materials compatible with hydrogen service and embrittlement resistance; fabrication/testing comply with ISO 11114, ISO 11120, and ISO 15869.

Industry Standard References

ISO 11114; ISO 11120; ISO 15869

Explosive Atmospheres (Hazardous Area Electrical)

ESSNA™ H59™ Specification

All electrical/electronic equipment within classified areas shall meet IEC 60079 requirements for selection, installation, and protection methods (Ex d, Ex e, Ex i).

Industry Standard References

IEC 60079 Series

Transport & Handling Standards

ESSNA™ H59™ Specification

Portable and transportable hydrogen storage systems shall meet ISO 16111 (metal hydride), ADR, and DOT CFR 49 requirements for packaging, relief devices, and safe carriage.

Industry Standard References

ISO 16111; ADR 2023; DOT CFR 49

Risk Assessment & Continuous Compliance

ESSNA™ H59™ Specification

Perform HAZOP and FMEA per ISO 19880-1 Annex G; maintain formal inspection, testing, and maintenance programs with audit intervals ≤ 12 months. Maintain ISO 9001 and ISO 14001 quality & environmental controls.

Industry Standard References

ISO 19880-1 Annex G; ISO 9001; ISO 14001