The ongoing evolution of hydrogen fuel systems for vehicles has necessitated robust standards to ensure reliability, and performance. Among the most critical of these standards is CSA/ANSI HGV 3.1:22, which outlines requirements for compressed hydrogen gas fuel system components in North America. Globally, ISO 19887:2024 is emerging as a de facto standard, borrowing heavily from HGV 3.1 while introducing its own specific parameters. For design engineers, understanding the differences between these standards is essential for designing solutions that meet diverse market requirements.
At Parker, our approach is shaped by decades of experience in compressed natural gas (CNG) systems, where we’ve cultivated a pragmatic, customer-centric methodology. This has taught us that simply meeting standards is not enough. To lead in the hydrogen market, we must go beyond compliance to anticipate real-world challenges, address customer concerns, and balance innovation with commercial viability.
Key differences between HGV 3.1 and ISO standards
HGV 3.1, revised as recently as 2022, sets validation testing benchmarks for a range of components, including check valves, manual and automatic valves, pressure regulators, hoses and fittings. ISO 19887 applies to a broader global market. Its stricter requirements in certain areas, such as permeation limits for hoses and material compatibility, challenge engineers to adopt innovative solutions. For example, while HGV 3.1 allows a hose permeation rate of up to 500 cc per meter per hour, ISO 19887 caps it at 20 cc, making material selection and design optimization critical.
For valves, ISO 19887 specifies 125% pressure at ambient temperature, including a filling cycle section, whereas HGV 3.1 mentions nominal working pressure without referencing a filling cycle. ISO also allows manufacturers to define lower limit voltage for valves to prevent unexpected activation due to leakage current, a provision absent in HGV 3.1. Both standards allow manufacturers to determine specifications like minimum operating temperature and maximum pressures. The key advantage of ISO 19887 lies in its status as an international standard, potentially offering broader acceptance compared to HGV 3.1.
Design engineers must recognize that decisions made for one standard may not automatically comply with the other. For instance, hoses using PTFE liners may struggle to meet ISO’s stringent permeation criteria. This illustrates the importance of aligning design decisions with target markets and their associated regulations.
Parker’s pragmatic approach: lessons from CNG
Our specialization in CNG systems serves as a valuable foundation for hydrogen fuel system development. With CNG, we faced similar challenges: sealing tiny, high-pressure molecules, ensuring durability under fluctuating temperatures and addressing risks around flammable gases.
Hydrogen, however, raises the bar. The molecule’s small size increases leakage risks, while its reactivity can weaken certain metals over time. Recognizing these unique challenges, we prioritize the following:
Exceeding standards
While HGV 3.1 and ISO 19887 provide a baseline, some of our products require additional validation for extreme applications, including extreme cold (-60°C) and rapid fueling/defueling cycles. For instance, our Seal-Lok™ fittings have been rigorously tested to exceed HGV 3.1’s requirements, ensuring reliability even in harsh environments.
Material innovation
Through collaboration across our business units, we’re developing advanced elastomers and thermoplastics tailored for hydrogen applications. These materials address concerns like rapid gas decompression and long-term exposure to high-pressure hydrogen.
Customer collaboration
By involving customers in the development process, we ensure our solutions address specific application needs without unnecessary overengineering. This approach accelerates time to launch and reduces iterations while building trust with end-users.
Balancing innovation and commercial viability
Hydrogen’s potential to decarbonize transportation is undeniable, but its path to widespread adoption faces hurdles, from infrastructure challenges to consumer perception. Risk reduction is a particularly significant concern, with fears around leakage and flammability affecting market acceptance.
Parker’s strategy emphasizes balancing cutting-edge innovation with practical, market-ready solutions. By leveraging our CNG experience, we’re developing hydrogen components that are not only reliable but also scalable for high-volume production. For example, our hydrogen dispensing hoses, already proven in commercial applications, reflect our commitment to delivering solutions that meet both current and future demands.
Preparing for the future
As hydrogen standards continue to evolve, Parker remains committed to staying ahead of the curve. By aligning our testing methods with ISO’s global perspective while exceeding HGV 3.1’s benchmarks, we’re positioning ourselves as a trusted partner for hydrogen system designers worldwide.
For engineers working in this emerging space, the following is clear: understand the standards, embrace pragmatism and focus on delivering value. With hydrogen poised to reshape the transportation industry, now is the time to build systems that inspire confidence and drive adoption. Parker’s decades-long commitment to innovation and quality ensures that as the hydrogen economy grows, our customers will have the tools and expertise to succeed. Whether designing valves, fittings or hoses, our focus remains the same: exceeding expectations, one application at a time.
