Standard for Fuel Systems in Fuel Cell and Other Hydrogen Vehicles

  • 2013-03-28
  • SAE International

The purpose of this document is to define design, construction, operational, and maintenance requirements for hydrogen fuel storage and handling systems in on-road vehicles.

Performance-based requirements for verification of design prototype and production hydrogen storage and handling systems are also defined in this document. Complementary test protocols (for use in type approval or self-certification) to qualify designs (and/or production) as meeting the specified performance requirements are described.

Crashworthiness of hydrogen storage and handling systems is beyond the scope of this document. SAE J2578 includes requirements relating to crashworthiness and vehicle integration for fuel cell vehicles. It defines recommended practices related to the integration of hydrogen storage and handling systems, fuel cell system, and electrical systems into the overall Fuel Cell Vehicle.

NOTE: Ultimate design qualification for crash impact resistance is achieved by demonstrated compliance of the vehicle with applicable regulations.


Section 5.2 and the referenced appendices (B, C, F, G, and H) were extensively revised to streamline and clarify requirements for the verification of Compressed Hydrogen Storage Systems (CHSSs). Detailed rationale for these revisions is provided in Appendix D. As part of these revisions, the fire test method for CHSSs was expanded to evaluate potential localized exposures during vehicle fires. Additionally, since the SAE FCV strives to develop performance-based requirements and eliminate the design prescription, new test methods have been developed for material compatibility in hydrogen service and stress rupture resistance and included in Appendices B and H, respectively, for guidance so that they can serve as a resource for design and development of vehicular hydrogen systems as well as basis for verification of the new methodologies.

The following other sections were also modified:

  • Section 3.18 was re-worded to harmonize with the CSA definition in HPRD1.
  • Section 4.4.1 was modified to add consideration of regulatory requirements to labeling.
  • Section has added requirements including the "pressure class" (H35, H70, etc.) labels
  • .
  • Section was deleted because a service limitation label is not a general requirement.
  • Section 4.4.5 was modified to correct a reference.
  • Finally, the following changes were made throughout the document:

  • The term "containment vessel" has replaced other terms such as "tanks" for consistency of nomenclature.
  • The use of "should" was replaced by "shall" in requirements judged to be mandatory and/or safety-critical. Such changes are consistent with the maturity of the document and the promotion of this document to a SAE Standard.
  • History:
    Standard Published Revision Status
    J2579_201303 2013-03-28 Latest Revised
    2009-01-06 Historical Revised
    2008-01-04 Historical Issued
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