Rules for Classification and Construction

VI Additional Rules and Guidelines

3 Machinery Installations

11 Guidelines for the Use of Fuel Cell Systems on Board of Ships and Boats

Edition 2003
 The following Guidelines come into force on March 1st, 2003

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VI - Part 3 Table of Contents Chapter 11
GL 2003 Page 3

Table of Contents

Section 1 General
A. Scope of Application .................................................................................................................. 1- 1
B. Applicable Rules ........................................................................................................................ 1- 1
C. Definitions .................................................................................................................................. 1- 2
D. Environmental Conditions .......................................................................................................... 1- 2
E. Fuels ........................................................................................................................................... 1- 2
F. Documents to be Submitted ....................................................................................................... 1- 3
G. Testing and Trials ....................................................................................................................... 1- 3
H. Power supply of Essential Consumers ........................................................................................ 1- 4
I. Installation .................................................................................................................................. 1- 4

Section 2 Materials
A. General Requirements ................................................................................................................ 2- 1
B. Approved Materials and Material Tests ..................................................................................... 2- 1

Section 3 Fuel Systems

A. Fuel Transfer System .................................................................................................................. 3- 1
B. Fuel Storage ............................................................................................................................... 3- 1
C. Fuel Conditioning ....................................................................................................................... 3- 2
D. Fuel Distribution ........................................................................................................................ 3- 3

Section 4 Fuel Cells and Associated Components

A. Installation .................................................................................................................................. 4- 1
B. Fuel Cell Stacks .......................................................................................................................... 4- 1
C. Inverters Following Fuel Cells ................................................................................................... 4- 1

Section 5 Ventilation Systems

A. General ....................................................................................................................................... 5- 1
B. Spaces with Mechanical Ventilation .......................................................................................... 5- 1
C. Gases and Vapours Heavier than Air ......................................................................................... 5- 1
D. Gases Lighter than Air ............................................................................................................... 5- 1
E. Ventilation Ducts for Fuel Pipes ................................................................................................ 5- 2
F. Double-Wall Piping System ....................................................................................................... 5- 2
G. Arrangement of the Supply Air and Exhaust Air Openings on Deck ......................................... 5- 2

Section 6 Fire Extinguishing Systems

A. General ....................................................................................................................................... 6- 1
Chapter 11 Table of Contents VI - Part 3
Page 4 GL 2003

Section 7 Explosion Protection

A. Explosion-Protected Systems ...................................................................................................... 7- 1
B. Classification into Zones ............................................................................................................. 7- 1

Section 8 Control, Regulating, Monitoring and Alarm Devices

A. Control and Operating Devices ................................................................................................... 8- 1
B. Automatic Control Devices ......................................................................................................... 8- 1
C. Monitoring and Alarm Devices ................................................................................................... 8- 1

Section 9 Protective Devices and Protective Systems

A. Protective Devices ...................................................................................................................... 9- 1
B. Protective Systems ...................................................................................................................... 9- 1
C. Safety Shut-Off Valves ............................................................................................................... 9- 2
D. Automatic Shut-Off Valve of Consumers ................................................................................... 9- 2

Section 10 Trials of the System

A. General ........................................................................................................................................ 10- 1
B. Trials of the Entire System .......................................................................................................... 10- 1
VI - Part 3 Section 1 B General Chapter 11
GL 2003 Page 1–1

Section 1

General

A. Scope of Application
Here the following apply in particular:
1. These Guidelines apply to the use of fuel-cell
systems (FC systems) permanently installed on ships Section 1 General Rules and Instructions
and boats. They describe the technical requirements
for the safe operation of FC systems. Section 8 Pressure Vessels

2. In the case of FC systems which are used as Section 9 Oil Firing Equipment
the sole means of propulsion, for the emergency elec-
trical supply or for the supply of essential consumers Section 10 Storage of Liquid Fuels, Lubricat-
in accordance with the GL Construction Rules, the ing, Hydraulic and Thermal Oils as
additional requirements will be determined within the well as Oil Residues
scope of an individual examination.
Section 11 Piping Systems, Valves and Pumps
3. Designs which deviate from these Guidelines
or from the applicable Rules may be approved if they Section 12 Fire Protection and Fire Extinguish-
are examined by GL for suitability and then approved ing Equipment
as being equivalent.
Section 15 Special Rules for Tankers
4. Deviating designs are necessary to some
extent for submersibles. These can be approved by
GL, especially with regard to the ventilation systems – Main Group I – Ship Technology
and pressure relief devices. Part 1 – Seagoing Ships

5. For water craft with FC systems conforming Chapter 3 – Electrical Installations

to these Guidelines and having a rated output greater Chapter 4 – Automation
than or equal to 10 % of the rated output of the ma-
chinery installation the class notation FC-xxx will be
assigned. The wild-card symbol "xxx" designates the – Main Group I – Ship Technology
percentage share of the FC system in relation to the
rated output of the machinery installation. Part 2 – Inland Waterway Vessels
For FC systems having a rated output lower than 10 % Chapter 2 – Machinery Installations
of the rated output of the machinery installation the
class notation with FC will be assigned. Chapter 3 – Electrical Installations

– Main Group I – Ship Technology

B. Applicable Rules
Part 3 – Special Craft
1. Rules for Classification and Construction
– Main Group II – Materials and Welding
In addition to these Guidelines, the following Rules
Part 1 – Metallic Materials
for Classification and Construction shall apply, if
applicable: Part 2 – Non metallic Materials
– Main Group I – Ship Technology Part 3 – Welding
Part 1 – Seagoing Ships
Chapter 1 – Hull Structures
2. Other rules
– Main Group I – Ship Technology
Part 1 – Seagoing Ships National and international regulations, such as
Chapter 2 – Machinery Installations SOLAS-74, MARPOL 73/74, IEC standards etc.
shall be observed, if applicable.
Chapter 11 Section 1 E General VI - Part 3
Page 1–2 GL 2003

C. Definitions quantity may be expected. Depending on the probabil-

ity of an explosive atmosphere, hazardous areas are
1. Alarm system classed as explosion zone 0, 1 or 2 according to
Section 7, B.
System for generating an alarm when the upper or
lower limiting values are transgressed. There is no
automatic intervention in the system. 6. Protective devices

2. Fuel cell Protective devices detect critical deviations from limit

values and prevent an immediate risk to persons, ship
A fuel cell is a source of electrical power in which the or machinery. In the event of a failure, protective
chemical energy of a fuel is converted directly into devices transfer the system into a safe state and pre-
electrical energy by electrochemical oxidation (also vent uncontrolled restarting.
known as "cold combustion").

7. Protective systems
3. Fuel cell stack
A fuel cell stack (FC stack) is a unit consisting of A protective system consists of the grouping of sev-
several fuel cells that are electrically connected in eral protective devices to form a functional unit.
series, with internal interconnections for electricity
and gas/liquid. An FC stack in the terms of these
Guidelines also includes the pipe connection fittings 8. Safe areas
as well as the connections required to supply the elec-
trical energy. Safe areas are the zones outside of the hazardous areas
of a ship.
4. Fuel cell system (FC system)
An FC system in terms of these Guidelines can com-
prise the following components:
D. Environmental Conditions
– fuel cell stacks
– arrangements for the transfer and storage of fuel, In the selection, design and arrangement of all compo-
including the necessary auxiliary equipment nents of FC systems on seagoing ships, the environ-
(e.g. heating/cooling) mental conditions described in the GL Construction
Rules, Main Group I – Ship Technology, Part 1 –
– arrangements for fuel distribution
Seagoing Ships, Chapter 2 – Machinery Installations,
– arrangements for fuel conditioning, including Section 1, C. shall be applied.
any reformer systems, gas humidifiers etc.
For FC systems on inland waterway vessels and
– installation spaces, including the ventilation
pleasure craft, the environmental conditions as per
systems
Main Group I, Part 2, Chapter 2, Section 1, C.3. and
– conditioning and storage of the oxidants (air or C.4. or Main Group I, Part 3, Chapter 3, Section 1,
oxygen) C.2. shall apply.
– electrolyte systems
– arrangements for the conditioning of residual
gas and exhaust gas
E. Fuels
– cooling systems
– interconnections between the systems 1. Fuels in terms of these Guidelines are the
– safety, regulating and monitoring equipment fuels kept in the storage tanks of the FC system as
well as the fuels available after conditioning or distri-
– electrical inverter systems bution.
– other auxiliary systems
– other energy converters integrated into the sys- 2. With the corresponding conditioning through
tem, e.g. gas turbines in systems with high- the reforming process, FC systems can be supplied
temperature fuel cells both with conventional marine fuels (flashpoint above
60 °C) and with fuels which have a flashpoint below
60 °C. The latter fuel types include, for example,
5. Hazardous areas (Ex zones)
methanol, liquefied gases such as LPG, the cryogenic
These are areas in which the accumulation of flamma- liquefied gases LNG and LH2, as well as pressurized
ble gases or vapours in a hazardous concentration or gases such as CNG, compressed hydrogen or propane.
VI - Part 3 Section 1 G General Chapter 11
GL 2003 Page 1–3

3. For the use of fuels with a flashpoint of 60 °C 4. Documents

or lower, the technical requirements specified in these
Guidelines shall apply. Additional requirements may The following documents shall be submitted in tripli-
be stipulated by GL. Furthermore, the consent of the cate.
competent approval authority (e.g. Flag State Admini-
stration) is required. Before production of the FC system commences:

– description of the process and function of the FC

4. For the use of fuels with a flashpoint above system
60 °C, the requirements specified in the GL Construc-
tion Rules, Main Group I, Part 1, Chapter 2, Section – piping and instrumentation diagrams, with block
10 and 11, shall apply. circuit diagrams of the overall system, including
parts lists or equipment lists

– technical documents of the components, includ-

F. Documents to be Submitted ing the fuel cell stacks themselves (descriptions,
specifications, verification of suitability accord-
1. General ing to existing standards and rules, approvals
and inspection certificates)
The technical documents shall permit an assessment of
the compliance of the system and its components with – electrical circuit diagrams, including the circuit
the applicable requirements of these Guidelines and of diagrams of the alarm system and the protective
other rules that must be met. Insofar as needed for the system
assessment, the documents shall cover the design,
production and functional principles, and shall permit – automation concept
a check that actual construction is in compliance with
the documentation. – fire extinguishing concept

Once the documents submitted have been approved, – plans of the hazardous areas (Ex zones)
they shall be binding. Any subsequent modifications
require GL approval prior to implementation. – safety and emergency concept, including a
safety analysis according to recognized proce-
dures, e.g. fault tree analysis, see F.2. and F.3.
2. Safety concept
It shall be demonstrated that Before the trials according to Section 10:
– operation manual
– the FC systems function safely when used for
their intended purpose including the mainte- – trials programme
nance activities
– malfunctions can be prevented with the aid of
the monitoring, alarm and protective devices
G. Testing and Trials
– dangerous operational situations which accord-
ing to general experience can arise, even though 1. General
the time of occurrence cannot be predicted (e.g.
critical deviations from limit values), and/or 1.1 FC systems are subject to the construction
which occur as a result of possible negligence supervision and acceptance testing by GL. Compli-
(e.g. foreseeable misuse) are brought under con- ance with the approved documents, the workmanship,
trol the suitability of the material and the documentation
– the effects of damage are limited by appropriate of the material characteristics as well as conformance
precautionary measures with the specification are checked.

3. Safety functions 1.2 GL reserves the right to extend the scope of

the tests, and also to subject to testing those parts
The documents submitted must show what technical which are not explicitly to be tested according to the
safety measures or solutions are effective for the op- Rules. For parts produced in series, the prescribed
erational situations stated under 2. In addition, it shall tests may be replaced by other tests agreed with GL.
be verified that the safety measures were selected
according to the following sequence of the criteria: 2. Test steps
– directly acting safety functions
The testing of an FC system by GL comprises the
– indirectly acting safety functions following steps:

– organizational safety precautions – evaluation of the technical concept

Chapter 11 Section 1 I General VI - Part 3
Page 1–4 GL 2003

– examination of the system documentation, the 3.3 A deviating procedure is only permissible if
technical documents for the components subject this is necessary for technical reasons and if it has
to mandatory testing, and the technical docu- been examined and approved by GL.
ments of the alarm and protective systems

– manufacturing tests, pressure tests and – if ap- H. Power supply of Essential Consumers
plicable – functional tests of parts and compo-
nents
If the FC system is used to supply essential consumers
– factory test of control, regulating and protective as per Main Group I, Part 1, Chapter 3, Section 1,
devices, and of protective systems, at the manu- B.2., B.3. and B.4., then verification of adequate reli-
facturer ability and fail-safety of the FC system shall be pro-
vided. The scope and type of the required verification
– functional test and completeness check of the is specified in each individual case by GL.
alarm and protective systems

– functional test and acceptance test of the overall I. Installation

system, including pressure and tightness tests
and completeness checks, see Section 10
1. FC systems shall be located in separate
– determination of the periodical tests, insofar as spaces. Installation in conventional machinery spaces
is not permitted.
these are not stipulated by the GL Classification
Rules The requirement for a separate space can also be met
by a suitable form of enclosure for the components
On successful execution of the above-mentioned test transferring the fuel. In such a case, installation in
steps, the proper construction and workmanship of the conventional machinery spaces is admissible.
system in accordance with the provisions of these
Guidelines is certified, and the Class Notation FC is
assigned. 2. Spaces in which fuel storage tanks are located
shall be separated from conventional machinery
spaces and the other parts of the FC system.
3. Pressure and tightness test

3.1 The piping systems and components shall be 3. Spaces in which components of the FC sys-
subjected to a hydrostatic pressure test with a test tem are installed shall be equipped with a mechanical
pressure equal to 1,5 times the maximum working ventilation system or other suitable ventilation devices
pressure as well as a tightness test with a test pressure of the extraction type as per Section 5. The spaces
equal to 0,9 times the maximum allowable working shall be monitored by gas detection systems as per
overpressure. Section 8, C. Special attention shall be paid to areas
with a low rate of air circulation.
3.2 The shut-off valves must be tested addition- Alternative constructions approved by GL as being
ally for tightness with 1,1 times the maximum allow- equivalent are permissible for submersibles and pleas-
able working overpressure. ure craft.
VI - Part 3 Section 2 B Materials Chapter 11
GL 2003 Page 2–1

Section 2

Materials

A. General Requirements – seagoing ships:

The materials shall be suitable for the intended appli- Main Group I, Part 1, Chapter 2, Section 8 and
cation and shall comply with recognized standards. Section 11
Their suitability shall be proven to GL. The use of
flammable materials is not allowed outside the FC – Inland waterway vessels:
stack. The Rules for Materials issued by GL shall be
observed. The use of flammable materials inside the Main Group I, Part 2, Chapter 2, Section 7 and
FC stack requires the approval of GL. Section 4, B.1. Section 10
shall be observed.
– pleasure craft:

Main Group I, Part 3, Chapter 3, Section 5

B. Approved Materials and Material Tests
Pipes for flammable liquids or gases shall be con-
For pressure vessels, piping, valves and pumps, the structed of suitable metallic materials. The use of
following requirements shall apply: other materials requires the consent of GL.
VI - Part 3 Section 3 B Fuel Systems Chapter 11
GL 2003 Page 3–1

Section 3

Fuel Systems

A. Fuel Transfer System 7. Entrances, ventilation openings and openings

leading to accommodation and service spaces,
machinery spaces, and control rooms shall be located
1. The fuel transfer systems include all outside hazardous areas. They shall not face the
components needed for filling the fuel tanks/con- bunkering station.
tainers. The connections to exchangeable tanks/con-
tainers shall be regarded as part of the fuel storage
system. 8. Openings to spaces which are located up to
10 m away from the transfer connection shall be kept
Fuel transfer systems shall be permanently installed,
closed during fuel transfer. Appropriate warning
completely separated from other pipeline systems, and
notices shall be displayed.
clearly marked.

2. The bunkering station shall be located on the

open deck.
B. Fuel Storage

3. The bunkering station and fuel transfer pipes

shall be provided with shut-off valves located directly 1. Fuel shall be stored in suitable tanks or
at the transfer point and directly before the distribution containers. Tanks/containers shall be secured against
manifold to the fuel tanks. The shut-off valves shall be the ship movements occurring during operation at sea.
designed in a way that they can be closed manually Proof of the suitability of the tanks/containers and
and by remote control. The position of the shut-off their securing arrangements shall be submitted to GL.
valve shall be indicated locally and in the control
room.
2. The installation spaces for tanks/containers
Remote-controlled valves and the position indicator in shall be located outside of accommodation, service
the control room are not required in the following and machinery spaces and of control rooms, and shall
cases: be separated from such spaces by gastight bulkheads.
If the installation space is adjacent to a space with
– fuel transfer systems with pipes up to 10 m in
potential fire load, separation by means of an A-60
length, if the nominal diameter is less than or
bulkhead is required. Tanks, which are part of the ship
equal to 12 mm
structure, shall be separated from other spaces by
– systems where a suitable non-return valve is means of cofferdams.
integrated into the pipe at the fuel transfer point
If it is necessary to deviate from this provision on
board small craft, the approval of GL is required.
4. A suitable fire extinguishing device shall be
provided in the vicinity of the bunkering station.
3. Entrances, openings and ventilation openings
to accommodation, service and machinery spaces and
5. If the fuel transfer system is installed in a safe
to control rooms shall be arranged at a distance of at
area according to Section 1, C.8., then measures shall
least 3 m from the openings of the installation space.
be taken to ensure that the fuel transfer pipe can be
gas-freed after use. Openings of blow-off pipes for
gas-freeing shall be arranged at points where no If it is necessary to deviate from this provision on
sources of ignition exist. small craft, the approval of GL is required.

6. During fuel transfer the requirements of zone 4. The ventilation and blow-off pipes of the
1 as per Section 7 shall apply for the immediate tanks shall be routed to the open air and so arranged
vicinity of the bunkering station. The immediate that the exhaust vapours and gases can be discharged
vicinity is defined as the space within a spherical without any danger. Up to a spherical radius of 3 m
radius of 3 m around the transfer connection. A around the outlet opening, there shall be no sources of
reduction of this distance is only permissible with the ignition or openings which lead to spaces containing
approval of GL. sources of ignition.
Chapter 11 Section 3 C Fuel Systems VI - Part 3
Page 3–2 GL 2003

Technically equivalent solutions are permissible, if it 2. Requirements for fuel conditioning

is not possible to vent vapours and gases to the open
air.
2.1 Compressors and pressure reduction
devices
5. Fuel tanks intended for liquefied and
pressurized gases and subjected to overpressure shall 2.1.1 It shall be possible to switch off the
be protected against inadmissible temperature compressors from a permanently accessible point
increases resulting from a fire in the vicinity. Fire outside the installation space. In addition, the
loads are not permissible within the installation space. compressor shall be stopped automatically if the
The installation space shall be protected against suction pressure is too low. The compressor shall not
inadmissible heating in the event of fire, by means of a be restarted automatically before a manual reset has
water sprinkler system or, alternatively, through A-60 been carried out.
fire insulation.
2.1.2 Positive displacement compressors shall be
If it is necessary to deviate from this provision on fitted with relief valves routed into the suction line of
small craft, the approval of GL is required. the compressors. The relief valves shall be so
dimensioned that, with the discharge of the
compressor in the closed position, the maximum
allowable working pressure is not exceeded by more
than 10 %.
C. Fuel Conditioning
2.1.3 Pressure reduction devices shall be so
designed that failure of a pressure reduction valve
1. General cannot endanger the downstream components. In
particular, the pipes downstream of the pressure
1.1 All components for conditioning the fuel – reducer shall be protected by safety valves or shall be
such as preheaters, compressors, filters, reformers etc. designed to a pressure rating corresponding to the
– shall be located in a closed space or a suitable maximum allowable working pressure that is
enclosure. This space or enclosure shall be ventilated permissible before the pressure reducer.
according to Section 5 and shall be equipped with a
gas detection system according to Section 8, C. and 2.2 Evaporators
Section 9.
2.2.1 Heating media for liquefied-gas evaporators
1.2 The installation spaces of the fuel or gas preheaters that are routed back into spaces
conditioning system shall be separated from the spaces located outside the area of the gas treatment plant shall
used for storage of the fuel. Doors between the spaces be passed through degassing containers which are
used for fuel storage and those used for fuel located within the hazardous area.
conditioning are not permitted.
2.2.2 A gas detection and alarm system shall be
provided within the degassing container.
1.3 In the pipes to the fuel conditioning system,
remote-controlled shut-offs, which can be closed from
outside the spaces, shall be arranged at the bulkheads. 2.2.3 The outlet opening of the vent pipe of the
degassing container shall be located in a safe area and
provided with an approved flame arrester.
1.4 The installation space shall be situated
outside of accommodation, service and machinery 2.3 Reformer Systems
spaces and control rooms, and shall be separated from
such spaces by means of a cofferdam or an A-60
bulkhead. Installation in a conventional machinery 2.3.1 General
space is admissible, on condition that a suitable
enclosure is provided. 2.3.1.1 Reformer systems shall be designed for
automatic operation and equipped with all the
indicating and control facilities required for
1.5 Entrances, openings and ventilation openings assessment and control of the process.
to accommodation, service and machinery spaces and
to control rooms shall be arranged at a distance of at 2.3.1.2 The chemical processes taking place within
least 3 m from the openings of the installation space the unit shall be monitored, see Section 8, C.3.
used for fuel conditioning, and shall not face them.
2.3.1.3 If limit values determined for the control
If it is necessary to deviate from this provision on process are exceeded, the unit must be switched off
small craft, the approval of GL is required and interlocked by an independent protective device.
VI - Part 3 Section 3 D Fuel Systems Chapter 11
GL 2003 Page 3–3

2.3.1.4 It shall be possible to switch off the reformer adequate distance from openings to accommodation,
unit from a permanently accessible point outside the machinery and service spaces.
installation space.
2.3.6 Residual gases
2.3.1.5 If high surface temperatures may occur, the
corresponding insulation or contact protection shall be The recirculation of fuel (residual gas) from the FC to
provided. the reformer is permissible. The recirculation shall be
protected by an automatic shut-off valve as per
2.3.2 Firing equipment Section 9, D.
2.3.2.1 For fuels in terms of these Guidelines, the GL
Construction Rules, Main Group I, Part 1, Chapter 2,
Section 9 – Oil Firing Equipment shall be applied as
appropriate. D. Fuel Distribution

2.3.2.2 Firing equipment in reformer systems shall

be designed for automatic operation. Manual operation 1. General
(even for emergencies) is not permissible.
1.1 Fuel pipes shall be independent of other
2.3.2.3 The firing equipment shall be equipped with piping systems. Use for other media than fuel has to
a type-tested burner control box and flame monitoring be prevented. Through their arrangement, it shall be
devices. Reliable operation of the flame monitoring ensured that they are protected against damage.
devices shall be verified for the corresponding type of
fuel and mode of combustion.
1.2 The fuel pipes between the supply tanks, the
2.3.2.4 After the firing equipment has been switched fuel conditioning system and the machinery space
off, the combustion chamber and the exhaust gas must be as short as possible. Fuel pipes shall be
system shall be purged with air or an inerting medium. arranged with the greatest possible horizontal distance
to the outer shell of the hull.
2.3.2.5 Depending on the type of fuel and the burner,
GL may define additional requirements for the firing 1.3 Fuel pipes shall not be routed through safe
equipment. areas, such as accommodation and service spaces or
2.3.2.6 The use of gaskets and insulating materials control rooms. If, in exceptional cases, fuel pipes have
which contain asbestos is not permissible. to be routed through a safe area, they shall be
constructed either as a double-wall piping system or as
2.3.3 Catalytic converters a pipe within the ventilation duct, see Section 5.

Catalytic converters in reformer units shall comply 1.4 Fuel pipes in hazardous areas can be arranged
with the GL Construction Rules in regard of the without a double pipe or outside of a ventilation duct,
environmental conditions to be considered, especially if they are located in a space/area ventilated according
the requirements related to vibration loading. For to Section 5 or in an enclosed housing which is
seagoing ships, the Rules as per Main Group I, Part 1, adequately ventilated and monitored, and if the
Chapter 1, Section 1 – General Rules and Instructions requirements for explosion protection as per Section 7
shall apply. are met.
2.3.4 Gas purification
2. Pipes for gaseous fuels
For installations as per Section 1, A.2., the gas purity
required for the operation of the fuel cell shall be
monitored by suitable methods. If the determined limit 2.1 Direct connections of pipes
values are exceeded, an alarm shall be generated or
the system shall be switched off. 2.1.1 Pipes shall be connected by butt welding with
full penetration.
If this requirement is not met for installations as per
Section 1, A.1., verification shall be provided that no 2.1.2 Screw fittings according to standards which
additional hazard can occur through inadmissible are approved by GL for this application can be used
impurities. for pipes with external diameters of 25 mm or less.
2.3.5 Exhaust gases
2.1.3 Flanged joints shall only be used at locations
The exhaust gases arising during the reforming where this is unavoidable. Only flange types approved
process shall be discharged safely to the open air at an by GL for that particular application shall be used.
Chapter 11 Section 3 D Fuel Systems VI - Part 3
Page 3–4 GL 2003

2.2 Flanged joints 2.2.3 With regard to type, make and quality
assurance, flanges shall comply with recognized
2.2.1 If flanged joints cannot be avoided in standards.
installation spaces, they are only permissible within
ventilated spaces and in areas in which ventilation of
the extraction type is provided, see Section 5.
2.3 Inerting
2.2.2 Flanged joints are permissible at the
bunkering station. It shall be possible to inert and gas-free the fuel pipes.
VI - Part 3 Section 4 C Fuel Cells and Associated Components Chapter 11
GL 2003 Page 4–1

Section 4

Fuel Cells and Associated Components

A. Installation vice and machinery spaces, and to control rooms and

other spaces containing sources of ignition.
1. All parts of fuel cells and the directly associ-
ated components containing fuel during normal opera- Alternative constructions approved by GL as being
tion shall be arranged in an enclosed space or suitable equivalent are permissible for submersibles and pleas-
enclosure. This space/enclosure shall be ventilated ure craft.
according to Section 5 and equipped with a gas detec-
tion system according to Section 8, C.2.
Alternative constructions approved by GL as being
equivalent are permissible for submersibles and pleas-
ure craft. B. Fuel Cell Stacks

2. The installation spaces of fuel cells and their 1. For FC stacks which have a total electrical
directly associated components shall be separated output greater than 1 MW and which contain flamma-
from the spaces used for fuel storage. Doors between ble materials, additional fire protection measures may
the spaces used for fuel storage and the installation be required by GL.
spaces of the fuel cells are not permissible.

3. The installation spaces of FC stacks and 2. If fuel cells are used for supplying essential
directly associated components shall be arranged out- consumers, then every fuel cell stack shall be sub-
side of accommodation, service and machinery spaces jected to a performance test at the manufacturer’s
and control rooms, and shall be separated from such works. The electrical output and the thermal output of
spaces by means of a cofferdam or an A-60 bulkhead. the fuel cells shall be verified by means of a suitable
Installation in a conventional machinery space is ad- performance test.
missible, on condition that a suitable enclosure is
provided.
3. If fuel cell stacks are used for supplying es-
4. Entrances, openings and ventilation openings sential consumers, then redundancy shall be ensured.
to accommodation, service and machinery spaces and
to control rooms shall be arranged at a distance of at
least 3 m from the openings of the installation space of
the fuel cells. The openings of the installation space
shall not face the entrances, openings and ventilation C. Inverters Following Fuel Cells
openings to accommodation, service and machinery
spaces and to control rooms.
If propulsion units or other essential consumers are
If it is necessary to deviate from this provision on supplied with electricity from FC systems, then the
small craft, the approval of GL is required. inverters shall be so designed that reverse power, such
as braking power, cannot pass into the fuel cells.
5. Openings for exhaust air and residual gases
of the FC stack shall be located on the open deck with In general, the requirements set out in the GL Con-
a horizontal distance of at least 3 m to any sources of struction Rules, Main Group I, Part 1, Chapter 3 ap-
ignition and to the openings of accommodation, ser- ply.
VI - Part 3 Section 5 D Ventilation Systems Chapter 11
GL 2003 Page 5–1

Section 5

Ventilation Systems

A. General 4. Air inlet and outlet openings shall be pro-

vided with fire dampers, which must be operable from
outside the spaces. Protective screens with a mesh
1. Spaces in which there is a risk that an ignit-
spacing of not more than 13 mm shall be mounted at
able gas mixture may be formed have to be equipped
the outer openings of ventilation ducts.
with mechanical ventilation systems of the extraction
type. Depending on the expected type of fuel release,
either the entire space or the hazardous areas must be 5. Fans shall not form a source of ignition nei-
fitted with suction ventilators. ther within the ventilated space nor within the ventila-
tion system connected to the space. Fans must be of a
For small installations, a natural ventilation arrange- non-sparking type and must comply with the GL Con-
ment can be approved by GL. struction Rules, Main Group I, Part 1, Chapter 2, Sec-
tion 15, B.5.3.
2. It must be possible to control the ventilation
systems from a point outside the ventilated spaces. 6. Fuel pipes that are routed into the ventilated
The spaces must be ventilated before access and be- space must be shut-off automatically by means of a
fore taking the equipment into operation. Notices must safety shut-off valve as per Section 9, C., if the re-
be provided outside the spaces, with the warning that quired air flow is not achieved or cannot be sustained,
the ventilation system must be switched on before or if a fuel leak is detected.
entering the spaces.

3. Ventilation systems must be permanently

installed. The ventilation systems are not allowed to C. Gases and Vapours Heavier than Air
be connected to those of other ship spaces.

1. The spaces shall be ventilated by means of

4. The extracted air must be monitored for fuel mechanically driven exhaust air fans. The supply air
constituents. The requirements set out in Section 8, shall be introduced into the upper part of the spaces.
C.2. apply.

2. The exhaust air duct shall be routed as

closely as possible to the floor of the space. The space
shall be so designed that gases collect at central points
B. Spaces with Mechanical Ventilation
from which they are extracted.

1. The inlet and outlet openings of the mechani-

cal ventilation system must be arranged in such loca-
tions that an adequate flow of air prevents the accumu- D. Gases Lighter than Air
lation of flammable vapours and ensures a safe work-
ing atmosphere throughout the entire room.
1. The spaces shall be ventilated by means of
mechanically driven exhaust air fans. The supply air
2. The ventilation system shall be designed for shall be introduced into the lower part of the spaces.
at least 30 air changes per hour with regard to the total
geometric volume of the empty space. If the ventila-
tion system fails, an alarm must be generated. Alterna- 2. The spaces hall be designed in such a way
tive constructions approved by GL as being equivalent that gases collect at the top at central points from
are permissible for submersibles and pleasure craft. which they are extracted.

3. Suitable design of the spaces shall ensure that 3. A suction hood or a suction trunk shall be
no gas can accumulate in recesses or pockets. provided for areas containing flanges, valves etc.
Chapter 11 Section 5 G Ventilation Systems VI - Part 3
Page 5–2 GL 2003

4. The suction hood or suction trunk shall be must be in the inner pipe. The space between the con-
arranged in such a way that the air flows around the centric pipes shall be pressurized with inert gas at a
gas-bearing components, and the air/gas mixture can pressure between the atmospheric pressure and the
be extracted at the upper part of the suction hood or fuel pressure. The outer pipe shall be designed for at
trunk. least the design pressure of the inner pipe.

As an alternative to this design for the outer pipe, a

pressure relief arrangement for the outer pipe can be
E. Ventilation Ducts for Fuel Pipes approved by GL, on condition that proof of equivalent
safety is provided. The pressure in the jacket pipe and
the triggering of the pressure relief device shall be
1. As an alternative to routing the fuel pipe monitored.
within a double-wall pipe as per F. the fuel pipe can
be laid in a tube or tunnel fitted with mechanical ven-
tilation of the extraction type. 2. In the event of an inadmissible pressure
change in the space between the two pipes, an alarm
2. Electrical cables are not permitted to pass must be triggered.
through this tube or tunnel.

3. The ventilated tunnel intended for the fuel

pipe shall be routed until a space is reached which is G. Arrangement of the Supply Air and Ex-
equipped with a ventilation system. haust Air Openings on Deck

4. The ventilation must be constantly in opera-

1. To prevent dangerous gases or vapours from
tion whenever fuel is present in the line. A gas detec-
being drawn in again, the supply air and exhaust air
tion unit shall be located in the extracted air stream
openings of the ventilation systems (to the outside
and be in permanent operation, in order to indicate any
atmosphere) on the open deck shall be arranged as far
leaks and to shut off the fuel supply automatically as
away from each other as possible. They shall be lo-
per Section 9, C. The safety shut-off valve must close
cated with a horizontal distance of at least 3 m to any
automatically whenever the required air flow is not
sources of ignition and to the openings of accommo-
achieved or cannot be sustained.
dation, service and machinery spaces, control rooms
and other spaces containing sources of ignition.
5. The ventilation system must be capable of
maintaining a pressure below atmospheric pressure. Alternative constructions approved by GL as being
The fan motors shall be arranged outside the venti- equivalent are permissible for submersibles and plea-
lated tube or tunnel. For the design of the fans, see sure craft.
B.5.

2. Exhaust air openings should be situated as far

away as possible from areas in which persons are
F. Double-Wall Piping System regularly to be found. These include, for example,
embarkation areas, muster stations for life-saving
appliances, deck work zones and passenger areas.
1. As an alternative to routing the fuel pipe
through a ventilation duct as per E. a double-wall pipe
can be used. In the case of double-wall pipes, the fuel 3. Exhaust air ducts must vent upwards.
VI - Part 3 Section 6 A Fire Extinguishing Systems Chapter 11
GL 2003 Page 6–1

Section 6

Fire Extinguishing Systems

A. General cell system, GL may request that a fire extinguishing

system be installed.

1. The area around the manifold for fuel transfer 2. The supply facilities of the fire extinguishing
and the installation spaces for systems in which fuels system shall always be arranged outside the spaces or
in terms of these Guidelines are used shall be areas which are to be protected. It must be possible to
equipped with fire extinguishing systems of a suitable set off the fire extinguishing system at a permanently
type. For all other spaces containing parts of the fuel accessible point.
VI - Part 3 Section 7 B Explosion Protection Chapter 11
GL 2003 Page 7–1

Section 7

Explosion Protection

A. Explosion-Protected Systems 2.4 Cables shall have armouring or shielding, or

shall be laid in a metallic tube.
1. Electrical equipment is regarded as being
explosion-protected if it has been manufactured ac- 3. Hazardous area, zone 1
cording to a recognized standard, e.g. the IEC 60079
publications or EN 50014 – 50020, and if it has been
inspected and approved by a recognized institution 3.1 Hazardous areas of zone 1 are areas in which
body. Any instructions and restrictions noted in the an ignitable gas mixture can be expected to be present
approval certificates shall be observed. occasionally. These areas can include e.g. spaces with
FC stacks, spaces with fuel tanks and pipes, spaces
with fuel conditioning systems, ventilation ducts of
2. With regard to the explosion protection, the pipes, and the monitoring space of double-wall pipes.
requirements set out in IEC 60079-14 shall be ob-
served. The required explosion group and temperature
class of the electrical equipment in the Ex zones de- 3.2 The extent of zone 1 shall be defined in com-
pend on the type of fuel, and shall be defined for each pliance with IEC 60079-10.
individual case.
3.3 For the electrical equipment in this area, only
explosion-protected units of a type suitable for ship-
board applications shall be used.
B. Classification into Zones
3.4 Cables shall have armouring or shielding, or
1. General shall be laid in a metallic tube.
Hazardous areas (Ex zones) shall be classified into
zones according to the probability of potentially ex- 4. Extended hazardous area, zone 2
plosive mixtures, in compliance with IEC 60079-10.
Extended hazardous areas of zone 2 are areas in which
Depending on the influence of the ventilation and its an ignitable gas mixture can be expected to be present
availability, an Ex area can be reclassified from its only very occasionally, and then only for a short pe-
original theoretical zone into an effective zone with a riod. Areas directly adjacent to zone 1 that are not
lower hazard level. separated in a gastight manner from zone 1 are as-
signed to zone 2. The extent of zone 2 shall be defined
in compliance with IEC 60079-10.
2. Hazardous area, zone 0
For electrical equipment in the areas belonging to
2.1 Hazardous areas of zone 0 are areas in which zone 2, protective measures should be taken depend-
an ignitable gas mixture must be expected to be pre- ing on the type and application of the equipment.
sent permanently. These areas include e.g. the inside These can comprise the following, for example:
of tanks or pipes containing flammable liquids with a
flash point ≤ 60 °C or with flammable gases. – explosion-protected equipment

– equipment with the degree of protection Ex n

2.2 Explosion zone 0 also includes the inside of
tanks, containers, heaters, pipes etc. for liquids or – equipment which generates no sparks in normal
fuels with a flashpoint above 60 °C, if these liquids operation, and where the surfaces exposed to the
are heated to more than 10° C below their flashpoint. outside air cannot reach inadmissible tempera-
tures
2.3 For electrical installations in these areas, only
– equipment which is contained in a pressurized
the following may be used:
enclosure in a simplified manner or enclosed in
– intrinsically safe electrical circuits with the a fume-tight enclosure (minimum protection
degree of protection Ex ia IP 55), where their surfaces cannot reach inad-
missible temperatures. The permissible tempera-
– equipment specially approved for use in this tures depend on the type of fuel, and shall be de-
zone fined for each individual case.
VI - Part 3 Section 8 C Control, Regulating, Monitoring and Alarm Devices Chapter 11
GL 2003 Page 8–1

Section 8

Control, Regulating, Monitoring and Alarm Devices

A. Control and Operating Devices C. Monitoring and Alarm Devices

1. If at least two control devices suited for the 1. General

operation of FC systems are stipulated by the GL
1.1 Alarm systems shall be provided which indi-
Construction Rules, Main Group I, Part 1, Chapter 3,
cate unacceptable deviations from normal operating
Section 9, B.3., then they shall function independently
figures by visible and audible alarms.
of each other and shall not affect each other in the
event of a failure. 1.2 Alarm delays shall be kept within time limits
which prevent any risk to the monitored system in the
2. The effects of the control actions must be event that a limit value is exceeded.
indicated at the control panel. If control actions can be
taken at several control units (control panels), the 1.3 Visible signals shall be individually indi-
following requirements shall be observed: cated.

– conflicting operator actions shall be prevented 1.4 In addition, the GL Construction Rules, Main
by means of suitable interlocks Group I, Part 1, Chapter 3, Section 9, C. shall be ob-
served.
– the control panel which is currently active must
be indicated appropriately 2. Gas detection system

2.1 Spaces in which gas leaks cannot be ruled out

3. Control devices should be designed in a way shall be monitored by gas detection systems. When a
that no serious damage or loss of essential functions concentration equal to 5 % of the lower explosion
can occur in the case of faulty operating actions. limit is reached, a visible and audible alarm must be
generated at the control station. When a concentration
4. It shall be ensured that the fuel cells can be equal to 10 % of the lower explosion limit is reached,
disconnected from the electrical load at any load con- a safety switch-off of the affected system must take
dition. place, see also Section 9, A.

2.2 Gas sensors must be arranged at all locations

where an accumulation of gases can be expected.
B. Automatic Control Devices
2.3 Gas detection systems are subject to approval
by GL.
1. For the FC systems, regulating devices shall
be provided to keep the process variables within the 3. Monitoring of chemical reactions
specified limits under normal operating conditions.
The regulating behaviour shall cover the entire range Chemical reactions, such as those taking place during
of operation. Parameter changes which can be antici- fuel conditioning and within the fuel cell, shall be
pated must be considered during the design phase. monitored, e.g. by means of temperature, pressure or
Faults in a regulating circuit shall not affect the proper voltage monitoring.
functioning of other regulating circuits. The power
supply to the regulating circuits shall be monitored 4. Monitoring the performance of the fuel
and an alarm must be generated on failure of the cells
power supply.
4.1 If an FC system is used to supply consumers
2. Regulating devices containing computers as per Section 1, A.2., then the electrical power pro-
shall be designed according to the GL Construction vided by the FC system shall be monitored.
Rules, Main Group I, Part 1, Chapter 3, Section 10.
4.2 In the case of load shedding, it shall be en-
sured that the FC system is automatically transferred
3. Regulating devices for fuel cell systems are into a safe condition from which it can be brought to
subject to mandatory type testing. the normal operating state again.
VI - Part 3 Section 9 B Protective Devices and Protective Systems Chapter 11
GL 2003 Page 9–1

Section 9

Protective Devices and Protective Systems

A. Protective Devices 9. It shall be ensured that the electric power

output can be switched off at any load condition, see
1. Protective devices shall be as simple as pos- Section 8, A.4.
sible, and must be reliable and direct in operation.
Where external energy is required for the function of 10. Protective devices are subject to mandatory
protective devices, the energy supply shall be moni- type testing.
tored for possible failure. The suitability and proper
function of protective devices must be demonstrated 11. The control and regulating devices on the one
for the given application. hand and the protective devices on the other shall be
located in separate spaces, so that, in the event of fire
2. Protective devices shall be designed in a way or water ingress, both systems are not adversely af-
that potential faults such as, for example, loss of volt- fected at the same time.
age or a broken wire, cannot create a hazard to human
life, ship or machinery. The occurrence of these faults
and also the tripping of protective devices shall be
indicated by an alarm. B. Protective Systems

3. Protective devices shall be designed to be

fail-safe. 1. General

4. The adjustment facilities for protective de- 1.1 A process-related interlinking of protective
vices shall be designed in a way that the last setting devices by the protective system shall not result in an
can be verified. impairment of the safety objectives.

5. Protective devices, including sensors and 1.2 When a protective system demands a re-
actuators, must be independent of control, regulating quirement class of 4 or higher according to the GL
and monitoring systems. Faults in one protective de- Construction Rules, Main Group I, Part 1, Chapter 3,
vice shall not affect any other protective device. Pro- Section 10, the following criteria shall be observed:
tective devices shall be assigned to the systems which
are to be protected. – The protective system should be of a fault-
tolerant design (multi-module).
6. The monitored open-circuit principle shall be – The modules should consist of different hard-
used for protective devices. Alternatively, the closed- ware.
circuit principle shall be applied where national regu-
lations demand it. Equivalent monitoring principles – If the modules contain software, this should be
are permitted. programmed according to different design crite-
ria and by different persons (redundancy
7. Faults occurring in protective devices must through diversity).
be indicated by an alarm.
1.3 Computers in protective systems shall be
8. In case of the following events, the affected designed according to the GL Construction Rules,
FC system must be switched off with due considera- Main Group I, Part 1, Chapter 3, Section 10.
tion to safety, and then locked out:
– emergency shutdown (protective device) 1.4 Protective systems for FC systems are subject
to mandatory type testing.
– gas detection: when a concentration equal to
10 % of the lower explosion limit is reached
1.5 The control and regulating devices on the one
– fire detection in hazardous areas hand and the protective system on the other shall be
– safety switch-off of the system owing to devia- located in separate spaces, so that, in the event of fire
tions from permissible operating parameters, in- or water ingress, both systems are not adversely af-
cluding chemical reactions fected at the same time.
Chapter 11 Section 9 D Protective Devices and Protective Systems VI - Part 3
Page 9–2 GL 2003

C. Safety Shut-Off Valves in series in the gas pipe leading to the consumer. By
means of the third shut-off valve, it shall be possible
1. Safety shut-off valves to relieve the pressure in the section of gas pipe lying
between the two shut-off valves. The vent pipe shall
Safety shut-off valves shall be provided at the follow- lead to the open air. For the outlet of the vent pipe, the
ing points of the fuel system: requirements set out in Section 3, B.4. apply.
– at the outlets from the fuel storage tanks
Alternative constructions approved by GL as being
– at the outlet from the fuel conditioning unit equivalent are permissible for submersibles and pleas-
– at the inlet of fuel pipes in monitored spaces ure craft.
– Depending on the structure of the system, addi-
tional safety shut-off valves may be required.
2. The shut-off valves must be arranged in a
way that actuation or failure of the control circuit of
2. It must be possible to close the safety shut-off the shut-off valves will cause the two series-connected
valves by means of the protective devices and also shut-off valves to close automatically and the vent
from a constantly manned position. They must be so valve to open automatically. Alternatively, the func-
constructed that they can only be reset manually. tion of one of the series-connected valves and the vent
valve can be incorporated into one valve body so
3. In the event of a leak, the fuel supply shall arranged that on actuation the flow to the gas con-
only be taken into operation again when the cause of sumer will be blocked and the vent line opened. The
the leak has been detected and remedied. Instructions three shut-off valves shall be constructed in a way that
on this requirement shall be displayed in a conspicu- they can only be reset by hand.
ous position in the installation space.

4. Safety shut-off valves have to be GL type- 3. The shut-off valves must close automatically
approved. under the following operating conditions:

– emergency shutdown
D. Automatic Shut-Off Valve of Consumers
– safety shutdown of the system
1. Each gas consumer (fuel cells, burners of
reformers etc.) must be fitted with a group of valves
consisting of three automatically actuated shut-off 4. It must be possible to actuate the shut-off
valves. Two of these shut-off valves must be located valves locally and also from any control panel.
VI - Part 3 Section 10 B Trials of the System Chapter 11
GL 2003 Page 10–1

Section 10

Trials of the System

A. General 3. Trials of the fire extinguishing system

Before the trials commence, a detailed trial The functional readiness of the fire extinguishing
programme shall be compiled. The trial programme is system shall be verified.
subject to approval by GL, see Section 1, F.
4. Functional trials of the FC system
The following operating conditions of the FC system
B. Trials of the Entire System shall be tested (as far as applicable):
The FC system shall be subjected to the following – automatic start-up of the FC system
trials after installation on board:
– operational switch-off of the FC system
1. Functional trials of components – load change, load steps
Safety shut-off valves, automatic shut-off valves, level – load shedding
indicators, temperature measurement devices, pressure
gauges, gas detection systems and alarm devices shall – switch-off during system malfunctions that do
be subjected to a functional trial. not endanger the safety of persons and
equipment
2. Trials of the protective devices and
protective system 5. Functional trials of the ship
During the trial, it shall be verified that, in the event of Within the scope of the functional trials, the
the following faults, the FC system is automatically interaction of the FC system with the ship systems
transferred into a safe condition: shall be tested as follows (as far as applicable):
– alarm of the fire detection devices – power generation by the FC system alone
– alarm of the gas detection system – FC system together with conventional shipboard
generation of electrical power
– failure of the power supply
– FC system together with batteries
– failure of the programmable logic controllers
(PLCs) – change-over to the emergency source of
– triggering of the protective devices electrical power

– faults in the protective devices – switching the FC system online or offline

– faults in the protective system If the FC system constitutes the main propulsion
system of the ship, it shall be verified that the ship has
It shall be verified that the requirements of the safety adequate propulsion power in all manoeuvring
analysis are met, see Section 1, F. situations