Remove and replace components in a hydrogen fuel cell electric vehicle system Legacy
Overview
This standard covers the competence and knowledge technicians need to safely carry out the removal and replacement of components in hydrogen fuel cell electric vehicle (FCEV) systems. The unit also ensures that the technician is aware of the hazards posed by hydrogen fuel cell electric vehicle systems and the safe working practices to follow when carrying out removal and replacement activities.
Warning: It has been recommended by industry experts that only those with suitable training and experience on working with electric vehicles should carry out the functions below.
Performance criteria
You must be able to:
P1 Identify that the vehicle has a hydrogen fuel cell electric vehicle system and collect relevant technical information
P2 Wear personal protective equipment (PPE) and use vehicle protection equipment (VPE) appropriate to the work activities you are carrying out
P3 Ensure the vehicle is safe to work on
P4 Ensure the work area is clearly identified using signs and barriers as appropriate, following environmental standards and regulations all times
P5 Support your work activities by reviewing:
P5.1 system manufacturer's vehicle technical data
P5.2 removal and replacement procedures
P5.3 legal requirements
P6 Prepare, check and use all the appropriate equipment required following manufacturer's instructions
P7 Work in a way which minimises the risk of:P7.1 damage to other vehicle systems, components and units
P7.2 damage to your working environment
P7.3 injury to yourself and others
P8 Select replacement components which meet the manufacturer's recommendations or conform to operating specification
P9 Carry out component removal and replacement activities following:P9.1 manufacturers’ instructions
P9.2 industry recognised repair methods
P9.3 health, safety and environmental requirements
P10 Record and report any relevant/related faults you notice during the course of your work
P11 Follow manufacturer’s instructions to test and evaluate the performance of the reassembled hydrogen fuel cell electric vehicle system accurately and ensure other associated systems operate correctly
P12 Ensure your records are accurate, complete and passed to the relevant person(s) promptly in the format required
Knowledge and Understanding
You need to know and understand:
Use of technical information
K1 The different types of hydrogen fuel cell electric vehicle systems and associated hydrogen storage systems
K2 How to find, interpret and use sources of information applicable to component removal and replacement within a hydrogen fuel cell electric vehicle system
K3 The importance of using the correct sources of technical information for hydrogen fuel cell electric vehicle component construction
Legislative and organisational requirements and procedures *
K4 The health and safety legislation, industry codes of practice or guidelines and workplace procedures relevant to working with hydrogen fuel cell electric vehicles
K5 How to select, check and use appropriate personal protective *equipment and vehicle protective equipment when working on hydrogen fuel cell electric vehicles
K6 How to ensure the environment is safe when working on a hydrogen fuel cell electric vehicle
K7 How to immobilise, store and mobilise a hydrogen fuel cell electric vehicle and its components safely in accordance with manufacturer’s recommendations
K8 Your workplace procedures for the:
K8.1 referral/reporting of problems when working with hydrogen fuel cell electric vehicles
K8.2 how to make others aware that work is being carried out on a hydrogen fuel cell electric vehicle
K9 The precautions necessary when using hydrogen re-fuelling equipment
K10 How to carry out a risk assessment on damaged and broken-down hydrogen fuel cell electric vehicles
K11 How to confirm a hydrogen fuel cell electric vehicle is safe to work on
K12 Hazards associated with hydrogen and hydrogen under high-pressure, including the physiological, mechanical and chemical effects of hydrogen
K13 The hazards associated with hydrogen fuel cell electric vehicles when exposed to extreme temperatures, impact and other adverse conditions
K14 The implications of electrical conductivity through the human body and the potential medical conditions that can occur regardless of voltage or current type present in a hydrogen fuel cell electric vehicle
K15 How to dispose of, recycle and return any removed hydrogen fuel cell electric vehicle system components in line with legislative, environmental and organisational requirements
K16 How to work safely avoiding damage to other vehicle systems, components and units and contact with leakage and hazardous substances
Hydrogen fuel cell and the vehicle system principles
K17 The basic construction of a hydrogen polymer electrolyte/proton-exchange membrane (PEM) fuel cell
K18 The electrochemical reactions in a PEM fuel cell
K19 The purpose of the membrane in a PEM fuel cell
K20 How a PEM fuel cell operates
K21 The by-products of the PEM fuel cell chemical reaction
K22 The differences between PEM fuel cell and other alternative fuel cell technologies which may come into general use
K23 The reasons for connecting PEM fuel cells into a stack
K24 On-board hydrogen fuel storage and supply systems
K25 The types of hydrogen production
Vehicle equipment faults and their correction
K26 How to identify faults and damage in hydrogen fuel cell electric vehicle systems and components
K27 How to remove, replace, test and evaluate the performance of components and the reassembled system against operating specifications and legal requirements
K28 The importance of ensuring components are functioning correctly before release to the customer
Hydrogen fuel cell electric vehicle systems and components
K29 How hydrogen supply system components function and are constructed
K30 How to identify the location of hydrogen and high-pressure hydrogen pipes and other system components, for example, by labelling or colour
K31 The different pressures and voltages associated with components in hydrogen fuel cell electric vehicles
K32 How hydrogen fuel cell electric vehicle systems interact with other vehicle systems
K33 The manufacturers'sspecification for the type and quality of components to be used for replacement
K34 The different types of energy storage systems and voltages associated with hydrogen fuel cell electric vehicles
K35 The ancillary components of alternative fuel sources and systems on hydrogen fuel cells
Use of tools and testing equipment and testing techniques
K36 How to select and use the testing equipment required
K37 How to select, prepare, check and use all the repair and replacement equipment required
K38 How to conduct tests on hydrogen fuel cell electric vehicle systems following safety and workplace procedures
K39 How to conduct a test on energy sources and systems
K40 How to determine the serviceability of a component in a hydrogen fuel cell electric vehicle system
K41 How to interpret the results of your tests and make recommendations based on these results
K42 The importance of basing your recommendations on test results
Vehicle system operation
K43 The main differences between a hydrogen fuel cell electric vehicle (FCEV) and a battery electric vehicle (BEV) and its operation
K44 How to safely operate a hydrogen fuel cell electric vehicle
K45 The specific manufacturer’s guidelines and the precautions necessary when charging, connecting an auxiliary power source to or towing/lifting an electric vehicle
K46 The evacuation and re-fuelling systems associated with hydrogen fuel cell electric vehicles and how to operate them safely
Scope/range
1. Equipment includes:
1.1. hand tools
1.2. code readers
1.3. special tools, for example manufacturer specific equipment and software
1.4. safe and appropriate electrical testing equipment
1.5. relevant safety equipment
1.6. hydrogen leak detector
1.7. hydrogen evacuation equipment
2. Testing methods include:
2.1. sensory
2.2. functional
2.3. measurement
3. Components include:
3.1. re-fuelling components
3.2. supply pipes
3.3. safety venting systems
3.4. valves and safety devices
3.5. storage tanks
3.6. insulation and protection methods and components
3.7. fuel cell stack
3.8. fuel cell components
3.9. electronic control units, sensors and actuators
3.10. driver inputs and instrumentation
3.11. pressure reduction devices
3.12. service items
Scope Performance
Scope Knowledge
Values
Behaviours
Skills
Glossary
This section contains examples and explanations of some of the terms used but does not form part of the standard.
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Fuel cell system
Includes fuel cell and fuel cell stack, hydrogen storage and supply, on-board fuelling systems and safety and control systems
Hazards associated with high voltage electrical vehicle components - exist not only during work on high voltage systems, as specified above, but also on all other high-power electrical drive systems and high-pressure storage systems. Vehicle and equipment manufacturers’ guidance should be followed at all times.
Hazards associated with hydrogen and hydrogen fuel cell electric vehicle systems *
Physiological (e.g. frostbite, respiratory ailments, injury from unexpected release of pressure and asphyxiation), mechanical (for example, embrittlement) and chemical (flammable - burns without visible flame, causes explosive atmospheres).
*High voltage – Regulation No 100 of the Economic Commission for Europe of the United Nations (UNECE) — Uniform provisions concerning the approval of vehicles with regard to specific requirements for the electric power train, states that: ‘High Voltage’ means the classification of an electric component or circuit, if its working voltage is > 60 V and ≤ 1 500 V DC or > 30 V and ≤ 1 000 V AC root mean square (rms). Electricity at Work Regulations (1989), and associated HSE guidance should be followed at all times.
Sensory testing methods
Include looking, listening, smelling, touching for temperature or vibration.
Sources of information applicable to electric vehicles
Examples include hard copy manuals, data on computer and data obtained from on- board diagnostic displays.
*Vehicle *
Fuel Cell Electric Vehicle (FCEV)