LIST AND STATUS OF EXISTING REGULATIONS, CODES AND STANDARDS (RCS)

Transcription

1 LIST AND STATUS OF EXISTING REGULATIONS, CODES AND STANDARDS (RCS) DELIVERABLE 6.1 May 29, 2013 Randy Dey Acknowledgement This project has received funding from the European Union s 7 th Framework Programme (FP/ ) for the Fuel Cells and Hydrogen Joint Technology Initiative under FCH-JU Grant Agreement Number The project partners would like to thank the EU for establishing the Fuel cells and hydrogen framework and for supporting this activity.

2 R E P O R T Disclaimer The staff of DeliverHy partners prepared this report. The views and conclusions expressed in this document are those of the staff of the respective DeliverHy partner(s). Neither the DeliverHy partner(s), nor any of their employees, contractors or subcontractors, makes any warranty, expressed or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, product, or process enclosed, or represents that its use would not infringe on privately owned rights.

3 List and Status of Existing Regulations, Codes and Standards (RCS) CONTENTS INTRODUCTION... II 1 OUTCOMES FROM WP2 AND WP4: WP WP CONCLUSIONS: APPENDIX: Transportable Composite H2 Storage List of active work Transportable Composite H2 Storage List of published documents i

4 List and Status of Existing Regulations, Codes and Standards (RCS) INTRODUCTION The objective of this WP6 is to summarize the findings and recommendations from the WP2-5 concerning the safe storage of compressed hydrogen in composite cylinders for the FCH community and to extract and prioritize recommendations to support RCS initiatives. ii

5 List and Status of Existing Regulations, Codes and Standards 1 OUTCOMES FROM WP2 AND WP4: 1.1 WP2 According to the D2.1 report, there is a need to reduce cost of transportation of hydrogen by using lighter composite material to allow transporting a larger amount (or payload) of hydrogen gas. This leads to the identification of challenges: Increasing water capacity, i.e. diameter of the vessels (cylinders or tubes) to increase volume increasing pressure of the transported gas reducing safety factor (burst pressure divided by design pressure) based on a well thought out rationale which is one of the important tasks of DeliverHy project. 1.2 WP4 The Deliverable 4.1 report identified RCS barriers and gaps. The key findings of technical barriers extracted from D4.1 are: - Need to secure that ADR will refer to ISO x standards for pressure vessels designated as cylinders in the standard but having a water capacity greater than 150 l but lower than 450 l, - Need to secure that ADR will refer to ISO11515 for tubes in composite material (Types 2, 3, and 4), - Need to ensure that the above standards implement the improved design requirements that are being developed, - Need to change or extend definition of tubes or create a new category of pressure vessel in ADR to cover the frame mounted tubes having a water capacity from 450 l up to l covered by ISO 17519, - Need to secure that ADR will refer to ISO for MEGC and trailers implementing tubes in composite material (Types 3 and 4) having a water capacity exceeding 450 l up to l, - Need to have inspection requirements for composite vessels determined only from requirements specified through ADR, 3

6 List and Status of Existing Regulations, Codes and Standards (RCS) - Need to have service life for composite vessels determined only on the basis of requirements included in the applicable standard covering design and manufacturing, - Need to develop and have ADR adopt standards providing adequate requirements for periodic inspection and testing for cylinders and tubes. 4

7 List and Status of Existing Regulations, Codes and Standards 2 CONCLUSIONS: As we continue to work on the remaining deliverables in DeliverHy, we expect the main conclusions to be more clear, focussed and with suitable rationale and justification of safety. In the meantime, D6.1 has prepared an updated list of existing active and published RCS taking into consideration the other standards and regulations that were discussed in other WPs but mainly WP4. See Appendix 1 and Appendix 2. A preliminary path forward that emerges is out of the work to date is firstly to identify the need to be revised e.g. ISO 1119, ISO and most importantly ongoing work in ISO The next step is to have the ADR refer to these revised versions of the standard. The DeliverHy recommendations for RCS and path forward will be elaborated based on final outcomes of WP2-5 along with interactions with authorities (WP7) to determine the most efficient process for acceptance of the RCS changes. 5

8 List and Status of Existing Regulations, Codes and Standards (RCS) 3 APPENDIX: 3.1 Transportable Composite H 2 Storage List of active work WG Work item Scope Remark Rev. ISO/TC 58/SC 3 WG 35 ISO/NP 17519; Gas cylinders Refillable permanently mounted composite tubes for transportation Edition 1 This International Standard defines minimum requirements for serially produced light-weight transportable tubes of composite construction permanently mounted in a transport frame intended for the bulk transport of pressurized gases. These tubes are from 450 liters to liters water capacity. The service conditions do not cover external loadings on the transport frame which may arise in transport. Those requirements are specifically provided in standards for the transport frame of which the composite tube is an integral part. The tube is required to meet any and all additional applied loads that are imposed by the specific frame design while in conformance to this International Standard. These tubes may also be suitable for ground storage. This International Standard covers tubes of filament-wound composite construction, using any design or method of manufacture suitable for the specified service conditions. Note: These composite cylinders are classified as tubes in many regulations and standards due their size (internal volume). The use of the term cylinder in this International Standard is intended as a generic term that can be used in place of tube. Cylinders covered by this International Standard are designated as follows1): Type IV 1 - a Fully Wrapped Cylinder with a nonload sharing liner and composite reinforcement on both the cylindrical part and the dome ends Not hydrogen specific Transportable Capacity: 450 l to l Type Consideration will be given to including Type 2 and Type 3 tubes of this size if issues related to acceptance of welds in structural liners can be resolved. 6

9 List and Status of Existing Regulations, Codes and Standards WG Work item Scope Remark Rev. ISO/TC 58/SC 3 WG 32 ISO/DIS Gas cylinders -- Refillable composite reinforced tubes of water capacity between 450 L and 3000 L -- Design, construction and testing Edition 1 This International Standard specifies minimum requirements for the design, construction and performance testing of composite reinforced tubes between 450 l and l water capacity, for the storage and conveyance of compressed or liquefied gases with test pressures up to and including 1600 bar with a design life of between 15 and 30 years. The expected service temperatures are between 40 C and + 65 C. The tubes in this standard are defined as one of three Types": Type 2 - a Hoop Wrapped Tube with a load sharing metal liner and composite reinforcement on the cylindrical portion only. Type 3 - a Fully Wrapped Tube with a load sharing metal liner and composite reinforcement on both the cylindrical portion and the dome ends. Type 4 - a Fully Wrapped Tube with a non-load sharing liner and composite reinforcement on both the cylindrical portion and the dome ends. Type 4 tubes manufactured and tested to this standard are not intended to contain toxic, oxidizing or corrosive gases. This standard is limited to tubes with composite reinforcement of carbon fibre or aramid fibre or glass fibre (or a mixture thereof) in a matrix. Composite tubes can be used alone or in batteries to equip trailers or skids (ISO modules) or MEGCs for the transportation and distribution of gases. This International Standard does not include consideration of any additional stresses that can occur during service or transport, e.g. torsional / bending stresses, etc. However it is important that the stresses associated with mounting the tube are considered by the assembly manufacturer and the tube manufacturer. Not hydrogen specific Transportable Capacity: 450 l to 3000 l Type 2, 3 and 4 7

10 List and Status of Existing Regulations, Codes and Standards (RCS) WG Work item Scope Remark Rev. ISO/TC 58/SC 3 WG 27 ISO/FDIS Gas cylinders -- Refillable composite gas cylinders and tubes -- Design, construction and testing -- Part 1: Hoop wrapped fibre reinforced composite gas cylinders and tubes up to 450 l Edition 2 This part of ISO specifies requirements for composite gas cylinders between 0.5 l and 150 l water capacity, for the storage and conveyance of compressed or liquefied gases. This International Standard is applicable to: Hoop wrapped composite cylinders with a seamless metallic liner and a design life from 10 years to non-limited life. The cylinders are constructed in the form of a liner over-wrapped with carbon fibre or aramid fibre or glass fibre (or a mixture thereof) in a matrix, or steel wire to provide circumferential reinforcement. NOTE Hoop wrapped composite cylinders are frequently referred to as Type 2 composite cylinders. This part of ISO does not address the design, fitting and performance of removable protective sleeves. Where these are fitted they should be considered separately. NOTE ISO applies to cylinders intended for use as fuel containers on natural gas vehicles and ISO covers periodic inspection and re-testing of composite cylinders. Not hydrogen specific Transportable Max capacity: 150 l Type 2 with seamless liner ISO/TC 58/SC 3 WG 27 ISO/FDIS Gas cylinders -- Refillable composite gas cylinders and tubes -- Design, construction and testing -- Part 2: Fully wrapped fibre reinforced composite gas cylinders and tubes up to 450 l with load-sharing metal liners Edition 2 This part of ISO specifies requirements for composite gas cylinders between 0.5 l and 150 l water capacity, for the storage and conveyance of compressed or liquefied gases. This International Standard is applicable to: Fully wrapped composite cylinders with a loadsharing liner (i.e. a liner that shares the load of the overall cylinder design) and a design life from 10 years to non-limited life. The cylinders are constructed in the form of a seamless liner over-wrapped with carbon fibre or aramid fibre or glass fibre (or a mixture thereof) in a matrix to provide longitudinal and circumferential reinforcement. NOTE Fully-wrapped composite cylinders with a load sharing liners are frequently referred to as 'Type 3' composite cylinders. This part of ISO does not address the design, fitting and performance of removable protective sleeves. Where these are fitted they should be considered separately. NOTE ISO applies to cylinders intended for use as fuel containers on natural gas vehicles and ISO covers periodic inspection and re-testing of composite cylinders. Not hydrogen specific Transportable Max capacity: 150 l Type 3 with seamless liner 8

11 List and Status of Existing Regulations, Codes and Standards WG Work item Scope Remark Rev. ISO/TC 58/SC 3 WG 27 ISO/DIS Gas cylinders of composite construction -- Specification and test methods Part 3: Fully wrapped fibre reinforced composite gas cylinders and tubes up to 450L with non-load-sharing metallic or nonmetallic liners Edition 2 This part of ISO specifies requirements for composite gas cylinders between 0.5 l and 150 l water capacity, for the storage and conveyance of compressed or liquefied gases This International Standard is applicable to: Fully wrapped composite cylinders with a nonload-sharing metallic or non-metallic liner (i.e. a liner that does not share the load of the overall cylinder design) and a design life from 10 years to non-limited life. The cylinders are constructed in the form of a liner over-wrapped with carbon fibre or aramid fibre or glass fibre (or a mixture thereof) in a matrix to provide longitudinal and circumferential reinforcement. NOTE Fully wrapped composite cylinders with non-load-sharing liners are frequently referred to as Type 4 composite cylinders. Composite cylinders without liners (including cylinders without liners manufactured from two parts joined together) and with a test pressure of less than 60 bar. The cylinders are constructed: 1) in the form of a disposable mandrel overwrapped with carbon fibre or aramid fibre or glass fibre (or a mixture thereof) in a matrix to provide longitudinal and circumferential reinforcement; 2) in the form of two filament wound shells joined together. This part of ISO does not address the design, fitting and performance of removable protective sleeves. Where these are fitted they should be considered separately. NOTE ISO applies to cylinders intended for use as fuel containers on natural gas vehicles and ISO covers periodic inspection and re-testing of composite cylinders Not hydrogen specific Transportable Max capacity: 150 l Type 4 9

12 List and Status of Existing Regulations, Codes and Standards (RCS) WG Work item Scope Remark Rev. ISO/TC 58/SC 3 WG 27 ISO/NP Gas cylinders of composite construction Specification and test methods Part 4: Fully-wrapped fibre reinforced composite gas cylinders with load-sharing welded metal liners Edition 1 This part of ISO specifies requirements for composite gas cylinders and tubes between 0.5 l and 450 l water capacity, for the storage and conveyance of compressed or liquefied gases. This International Standard is applicable to: Fully wrapped composite cylinders with a load-sharing welded liner (i.e. a liner that shares the load of the overall cylinder design) and a design life from 10 years to non-limited life. The cylinders are constructed in the form of a welded stainless steel liner or welded ferritic steel liner or friction stirred welded aluminium liner or welded titanium liner over-wrapped with carbon fibre or aramid fibre or glass fibre (or a mixture thereof) in a matrix to provide longitudinal and circumferential reinforcement. This part of ISO specifies requirements for composite gas cylinders between 0.5 l and 150 l water capacity, for the storage and conveyance of compressed or liquefied gases. NOTE Fully-wrapped composite cylinders with a load sharing liners are frequently referred to as 'Type 3' composite cylinders. This part of ISO does not address the design, fitting and performance of removable protective sleeves. Where these are fitted they should be considered separately. NOTE ISO applies to cylinders intended for use as fuel containers on natural gas vehicles and ISO covers periodic inspection and re-testing of composite cylinders. Not hydrogen specific Transportable Max capacity: 150 l Type 3 with welded liners ISO/TC 58/SC 3 WG 24 ISO/TR Gas Cylinders - Guidance for design of composite cylinders - Part 2: Cyclic fatigue of fibers and liners, calculation of stress ratios, and bonfire test issues Edition 1 This proposed second part of the Technical Report on Guidance for Design of Composite Cylinders will be focussed on topics which the industry has brought forward as being of benefit in the continued development of composite cylinder standards, specifically the cyclic fatigue of reinforcing fibers and the liners of composite cylinders, methods for calculating stress ratios, and issues relating to bonfire testing of composite cylinders. ISO/TC 58/SC 4 ISO/CD Transportable gas cylinders -- Periodic inspection and testing of composite gas cylinders Edition 2 Revision of ISO 11623:

13 List and Status of Existing Regulations, Codes and Standards WG Work item Scope Remark Rev. ISO/TC 58/SC 4 ISO/DIS Gas cylinders -- Inspection of the cylinder installation, and requalification of high pressure cylinders for the onboard storage of natural gas as a fuel for automotive vehicles Edition 2 Revision of ISO 19078:2006. ISO/TC 58 WG 7 ISO/NWIP Testing methods used for evaluating steels exposed to hydrogen gas Review of test data The objective of this report consists in establishing a state-of-the-art regarding test methods used to select steels exposed to hydrogen. The data exchanged to prepare this Technical Report is limited to tests performed only with H2. Test data for other embrittling gases are not considered in this report. This will be based on papers presented at the three meetings, as well as literature data made available 1). After briefly going through general points regarding hydrogen embrittlement, test methods will be described, with their respective strengths and weaknesses. Then experimental results based on test methods comparison will be reviewed. 11

14 List and Status of Existing Regulations, Codes and Standards (RCS) WG Work item Scope Remark Rev. ISO/TC 197 WG 6 ISO/DIS15869 Gaseous hydrogen and hydrogen blends Land vehicle fuel tanks Edition 1 To supersedes ISO/TS This International Standard specifies the requirements for lightweight refillable fuel tanks intended for the on-board storage of highpressure compressed gaseous hydrogen or hydrogen blends on land vehicles 2. This International Standard is not intended as a specification for fuel tanks used for solid, liquid hydrogen or hybrid cryogenic-high pressure hydrogen storage applications. This International Standard is applicable for fuel tanks of steel, stainless steel, aluminium or nonmetallic construction material, using any design or method of manufacture suitable for its specified service conditions. This Standard applies to the following types of fuel tank designs: Type 1 all - metal fuel tank; Hydrogen specific Onboard storage Types 1, 2, 3 and 4 with seamless liners as well as welded aluminium liner Type 2 hoop wrapped fuel tank with a load sharing metal liner and composite reinforcement on the cylindrical part only; Type 3 fully wrapped fuel tank with a load sharing metal liner and composite reinforcement on both the cylindrical part and dome ends; Type 4 fully wrapped fuel tank with a non-load sharing liner and composite reinforcement in both the cylindrical part and dome ends. 2 The first edition of this International Standard only covers gaseous hydrogen fuel tanks for use onboard light duty four-wheel passenger road vehicles and heavy-duty road vehicles. Fuel tanks for other applications as well as fuel tanks for storing hydrogen blends are to be added in the next editions. 12

15 List and Status of Existing Regulations, Codes and Standards 3.2 Transportable Composite H 2 Storage List of published documents Publications Scope Rev. 1999/36/EC COUNCIL DIRECTIVE 1999/36/EC of 29 April 1999 on transportable pressure equipment (TPED) 1. The purpose of this Directive shall be to enhance safety with regard to transportable pressure equipment approved for the inland transport of dangerous goods by road and by rail and to ensure the free movement of such equipment within the Community, including the placing on the market and repeated putting into service and repeated use aspects. 2. This Directive shall apply: (a) for the purpose of placing on the market: to new transportable pressure equipment as defined in Article 2; (b) for the purpose of reassessment of conformity: to existing transportable pressure equipment as defined in Article 2 which meets the technical requirements laid down in Directives 94/55/EC and 96/49/EC; (c) for repeated use and periodic inspections: - to the transportable pressure equipment referred to in (a) and (b), - to existing gas cylinders bearing the conformity marking laid down in Directives 84/525/EEC, 84/526/EEC and 84/527/EEC. 13

16 List and Status of Existing Regulations, Codes and Standards (RCS) Publications Scope Rev. UN Model Regulations UN Recommendations on the Transport of Dangerous Goods - Model Regulations, 17 Edition 1. These Recommendations have been developed by the United Nations Economic and Social Council's Committee of Experts on the Transport of Dangerous Goods in the light of technical progress, the advent of new substances and materials, the exigencies of modern transport systems and, above all, the requirement to ensure the safety of people, property and the environment. They are addressed to governments and international organizations concerned with the regulation of the transport of dangerous goods. They do not apply to the bulk transport of dangerous goods in sea-going or inland navigation bulk carriers or tank-vessels, which is subject to special international or national regulations. 2. The recommendations concerning the transport of dangerous goods are presented in the form of "Model Regulations on the Transport of Dangerous Goods", which are presented as annex to this document. The Model Regulations aim at presenting a basic scheme of provisions that will allow uniform development of national and international regulations governing the various modes of transport; yet they remain flexible enough to accommodate any special requirements that might have to be met. It is expected that governments, intergovernmental organizations and other international organizations, when revising or developing regulations for which they are responsible, will conform to the principles laid down in these Model Regulations, thus contributing to worldwide harmonization in this field. Furthermore, the new structure, format and content should be followed to the greatest extent possible in order to create a more user-friendly approach, to facilitate the work of enforcement bodies and to reduce the administrative burden. Although only a recommendation, the Model Regulations have been drafted in the mandatory sense (i.e., the word "shall" is employed throughout the text rather than "should") in order to facilitate direct use of the Model Regulations as a basis for national and international transport regulations. 3. The scope of the Model Regulations should ensure their value for all who are directly or indirectly concerned with the transport of dangerous goods. Amongst other aspects, the Model Regulations cover principles of classification and definition of classes, listing of the principal dangerous goods, general packing requirements, testing procedures, marking, labelling or placarding, and transport documents. There are, in addition, special requirements related to particular classes of goods. With this system of classification, listing, packing, marking, labelling, placarding and documentation in general use, carriers, consignors and inspecting authorities will benefit from simplified transport, handling and control and from a reduction in time-consuming formalities. In general, their task will be facilitated and obstacles to the international transport of such goods reduced accordingly. At the same time, the advantages will become increasingly evident as trade in goods categorized as "dangerous" steadily grows. 14

17 List and Status of Existing Regulations, Codes and Standards Publications Scope Rev. European Agreement concerning the International Carriage of Dangerous Goods by Road (ADR) 2011 German Act on the Transport of Dangerous Goods (atd) ISO/TR :2011 Gas cylinders Guidance for design of composite cylinders Part 1: Stress rupture of fibres and burst ratios related to test pressure Edition 1 ISO :2005 Transportable gas cylinders -- Compatibility of cylinder and valve materials with gas contents -- Part 4: Test methods for selecting metallic materials resistant to hydrogen embrittlement Editon 1 The European Agreement concerning the International Carriage of Dangerous Goods by Road (ADR) was done at Geneva on 30 September 1957 under the auspices of the United Nations Economic Commission for Europe, and it entered into force on 29 January The Agreement itself was amended by the Protocol amending article 14 (3) done at New York on 21 August 1975, which entered into force on 19 April The Agreement itself is short and simple. The key article is the second, which say that apart from some excessively dangerous goods, other dangerous goods may be carried internationally in road vehicles subject to compliance with: the conditions laid down in Annex A for the goods in question, in particular as regards their packaging and labelling; and the conditions laid down in Annex B, in particular as regards the construction, equipment and operation of the vehicle carrying the goods in question. Annexes A and B have been regularly amended and updated since the entry into force of ADR. Consequently to the amendments for entry into force on 1 January 2011, a revised consolidated version has been published as document ECE/TRANS/215, Vol. I and II- N/A This part of ISO/TR gives guidance for the design of composite cylinders, relating to stress rupture reliability and burst ratio as a function of test pressure. Related issues, such as cyclic fatigue of the liner and composite, damage tolerance, environmental exposure, and life extension will be addressed in subsequent parts. The topics covered by this part of ISO/TR are to support the development and revision of standards for fibre composite reinforced pressurized cylinders. ISO :2005 specifies test methods and the evaluation of results from these tests in order to qualify steels suitable for use in the manufacture of gas cylinders (up to l) for hydrogen and other embrittling gases. ISO :2005 only applies to seamless steel gas cylinders. The requirements of ISO :2005 are not applicable if at least one of the following conditions for the intended gas service is fulfilled: the working pressure of the filled embrittling gas is less than 20 % of the test pressure of the cylinder; the partial pressure of the filled embrittling gas of a gas mixture is less than 5 MPa (50 bar) in the case of hydrogen and other embrittling gases, with the exception of hydrogen sulphide and methyl mercaptan in which cases the partial pressure shall not exceed 0,25 MPa (2,5 bar). 15

18 List and Status of Existing Regulations, Codes and Standards (RCS) Publications Scope Rev. ISO :2002 Gas cylinders of composite construction - Specification and test methods - Part 1: Fully wrapped fibre reinforced composite gas cylinders with load-sharing metal liners Edition 1 ISO :2002 Gas cylinders of composite construction - Specification and test methods - Part 2: Fully wrapped fibre reinforced composite gas cylinders with load-sharing metal liners Edition 1 ISO :2002 Gas cylinders of composite construction - Specification and test methods - Part 3: Fully wrapped fibre reinforced composite gas cylinders with load-sharing metal liners Edition 1 ISO 11623:2002 Transportable gas cylinders -- Periodic inspection and testing of composite gas cylinders Edition 1 ISO specifies requirements for composite gas cylinders up to and including 450 litres water capacity, for the storage and conveyance of compressed or liquefied gases with test pressures up to and including 650 bar. The cylinders are constructed in the form of a seamless metallic liner overwrapped with carbon fibre or aramid fibre or glass fibre (or a mixture thereof) in a resin matrix, or steel wire, to provide circumferential reinforcement. This part of ISO addresses cylinders with a design life from 10 a to nonlimited life. For cylinders with a design life in excess of 15 a, and in order for these cylinders to remain in service beyond 15 a, re-qualification of these cylinders is recommended. This part of ISO does not address the design, fitting and performance of removable protective sleeves. Where these are fitted they should be considered separately. ISO specifies requirements for composite gas cylinders up to and including 450 litres water capacity, for the storage and conveyance of compressed or liquefied gases with test pressures up to and including 650 bar. The cylinders are constructed in the form of a seamless metallic liner overwrapped with carbon fibre or aramid fibre or glass fibre (or a mixture thereof) in a resin matrix, or steel wire, to provide circumferential reinforcement. This part of ISO refers to fully wrapped composite cylinders with a loadsharing liner (i.e. a liner that shares the load of the overall cylinder design) and a design life from 10 a to non-limited life. For cylinders with design life in excess of 15 a, and in order for these cylinders to remain in service beyond 15 a, requalification of these cylinders is recommended. This part of ISO does not address the design, fitting and performance of removable protective sleeves. Where these are fitted they should be considered separately. ISO specifies requirements for composite gas cylinders up to and including 450 l water capacity, for the storage and conveyance of compressed or liquefied gases with test pressures ranging up to and including 650 bar. ISO applies to: 1. Fully wrapped composite cylinders with a non-load-sharing metallic or nonmetallic liner (i.e. a liner that does not share the load of the overall cylinder design) and a design life from 10 years to non-limited life. 2. Composite cylinders without liners (including cylinders without liners manufactured from two parts joined together) and with a test pressure of less than 60 bar. The cylinders are constructed: 1. in the form of a disposable mandrel overwrapped with carbon fibre or aramid fibre or glass fibre (or a mixture thereof) in a resin matrix to provide longitudinal and circumferential reinforcement; 2. in the form of two filament wound shells joined together. ISO does not address the design, fitting and performance of removable protective sleeves. N/A 16

19 List and Status of Existing Regulations, Codes and Standards Publications Scope Rev. ISO 19078:2006 Gas cylinders -- Inspection of the cylinder installation, and requalification of high pressure cylinders for the onboard storage of natural gas as a fuel for automotive vehicles Edition 1 ASME BPVC-XII 2010 BPVC Section XII-Rules for Construction and Continued Service of Transport Tanks ASME STP-PT-003 Hydrogen Standardization Interim Report for Tanks, Piping, and Pipelines ASME STP-PT-004 Impregnated Graphite for Pressure Vessels ISO 19078:2006 specifies the requirements for the inspection of the cylinder installation and the requalification of high pressure cylinders, designed and manufactured in accordance with ISO 11439, for the on-board storage of natural gas as a fuel for automotive vehicles. The purpose of ISO 19078:2006 is to provide guidance for the inspection of these cylinders in accordance with the manufacturer's recommendations, and to provide criteria for acceptance or rejection in the absence of guidance from the manufacturer, with subsequent disposition as necessary. This section covers requirements for construction and continued service of pressure vessels for the transportation of dangerous goods via highway, rail, air or water at pressures from full vacuum to 3,000 psig and volumes greater than 120 gallons. "Construction" is an all-inclusive term comprising materials, design, fabrication, examination, inspection, testing, certification, and over-pressure protection. "Continued service" is an all-inclusive term referring to inspection, testing, repair, alteration, and recertification of a transport tank that has been in service. This section contains modal appendices containing requirements for vessels used in specific transport modes and service applications. Rules pertaining to the use of the T Code symbol stamp are included. This interim report is intended to address priority topical areas with pressure technology applications for hydrogen infrastructure development. The scope of this interim report includes addressing standardization issues related storage tanks, transportation tanks, portable tanks, and piping and pipelines. It is anticipated that the contents and recommendation of this report may be revised as further research and development becomes available. The scope for the tank portions of this report (Parts I and II) includes review of existing standards, comparison with ASME Boiler and Pressure Vessel Code (BPVC) Section VIII, and recommendations for appropriate design requirements applicable to small and large vessels for high strength applications up to 15,000 psi. This report also includes identification of design, manufacturing, and testing issues related to use of existing pressure vessel standards for high strength applications up to 15,000 psi, identification of commonly used materials, and developing data for successful service experience of vessels in H2 service. Similarly, the scope of piping and pipelines portion of this report (Part III) includes reviewing existing codes and standards, recommending appropriate design margins and rules for pressure design up to 15,000 psi, reviewing the effects of H2 on commonly used materials, developing data for successful service experience, researching leak tightness performance, investigating effects of surface condition of piping components, and investigating piping/tubing bending issues. Impregnated graphite (also called impervious graphite) is a material that has been in industrial use for the past years. The primary industrial use has been in the construction of chemical processing equipment where the exceptional corrosion resistance and high thermal conductivity of graphite is particularly advantageous. Typical applications include the manufacture of pharmaceuticals and phosphate fertilizer, steel pickling, processing of chlorinated organics, flue gas treatment, HCI and H2SO4 production and recovery, plus the manufacture of chemical intermediates. The impervious graphite used for the construction of graphite pressure vessels is a composite material, consisting of "raw" graphite that is impregnated with a resin using a tightly controlled pressure/heat cycle. 17

20 List and Status of Existing Regulations, Codes and Standards (RCS) Publications Scope Rev. ASME STP-PT-005 Design Factor Guidelines for High- Pressure Composite Hydrogen Tanks ASME STP-PT-014 Data Supporting Composite Tank Standards Development for Hydrogen Infrastructure Applications This report provides recommendations to the ASME Hydrogen Project Team for design factors for composite hydrogen tanks. The scope of this study included stationary (e.g., storage) and transport tanks; it does not include vehicle fuel tanks. The report provides recommended design factors relative to short-term burst pressure and interim margins for long-term stress rupture based on a fixed 15-year design life for fully wrapped and hoop wrapped composite tanks with metal liners. These recommended margins are based on the proven experience with existing standards for composite reinforced tanks. Recommendations for further research are also provided, in particular for development of rules that would provide design life dependent design factors relative to stress rupture that would provide a means to design for longer or shorter lives than 15 years, and to provide a method for the manufacturer to determine, by testing, the stress ratio for their fiber reinforcement system. Composite cylinders have been used for over 50 years in commercial, vehicle, defense and aerospace applications. New materials, processes, design approaches and applications have been incorporated during that time. The industry has maintained a high level of safety. The industry has adapted to these changes and has developed new and revised standards to address these changes and to reflect a better understanding of service conditions. Recommendations are made that the industry: Continue to monitor field use and incorporate changes to requirements, standards and codes that reflect knowledge gained for composite pressure vessels, Use a failure modes and effects analysis (FMEA) approach to standards, using the knowledge gained from field experience, Develop standards for composite pressure vessels that are more performance based to improve both safety and performance, Address requirements using performance testing, not by using excessive safety factors, Use stress ratios for the various reinforcing fibers that accurately reflect their stress rupture and fatigue characteristics to achieve high reliability, Harmonize testing requirements where practical, Use qualification tests that are appropriate for the application and for the materials and design features of the pressure vessels being used, and Consider using fleet leader programs for new materials, designs or applications if there is likely to be a significant safety issue To support these recommendations, history of use of composite cylinder in aerospace/defense, commercial and vehicle applications is reviewed. This includes review of applications, materials of construction; standards used and field service issues. The use of performance-based requirements is discussed, as is the background of safety factors used for various reinforcing fibers. Recommendations are made for validation testing of materials and pressure vessels, with consideration for failure modes and effects analysis (FMEA) involving the field use of the vessels. Cyclic fatigue and stress rupture are discussed, with examples of laboratory testing and correlation from field experience. 18

21 List and Status of Existing Regulations, Codes and Standards Publications Scope Rev. ASME STP-PT-017 Properties for Composite Materials in Hydrogen Service Studies were conducted to address three specific questions related to the use of composite-reinforced pressure vessel designs for the transportation of compressed hydrogen at pressures up to 103 MPa (15,000 psi). These studies involved determining the hydrogen embrittlement resistance of AA6061-T6 aluminum alloy material typically used as a liner in composite-reinforced cylinder designs; determining whether composite-reinforced pressure vessels using plastic or thin-wall metallic liners were subject to distortion during the filament winding process; and identifying test methods that can be used to establish the long-term performance of non-metallic materials exposed to high-pressure hydrogen environments. Long-term hydrogen embrittlement tests were conducted on AA6061-T6 samples using compact tension specimens according to ISO , Method C. Specimens were fatigue pre-cracked, following which the fatigue cracks were preloaded to various stress intensity factors. The specimens were then inserted into a pressure vessel containing hydrogen at 103 MPa (15,000 psi). After 1,000 hours exposure, there was no evidence observed of any hydrogen-induced crack growth in the aluminum. A variety of composite-reinforced pressure vessels that use plastic liners and thinwalled aluminum liners, and having lengths up to 3058 mm, were inspected. There was no evidence of any axial distortion. In addition, pressure cycle and burst test data between composite-reinforced pressure vessels of relatively short length and relatively long length were compared, confirming that the designs of different length had the same performance. Plastic liner materials cut from four high-pressure hydrogen storage tanks of different design were tested for effects of high-temperature ageing and of longterm exposure to high-pressure hydrogen. Specimens were tensile tested in the as-received condition, after one-month exposure to 70 MPa (10,000 psi) hydrogen and after one-month exposure to 85 C atmosphere. The 70 MPa hydrogen exposure for 30 days had no noticeable effect on the strength of the materials but did create some bubbles in the surface. On average, ageing three of the materials for 30 days at 85 C caused an increase in tensile strength. It was concluded that more samples needed to be tested to develop a more acceptable statistic average of the mechanical properties, and that full-scale testing should be performed on complete pressure vessels at both high and low service temperatures with hydrogen pressure. 19

22 List and Status of Existing Regulations, Codes and Standards (RCS) Publications Scope Rev. ASME STP-PT-021 Nondestructive Testing and Evaluation Methods for Composite Hydrogen Tanks This report includes a study of various nondestructive evaluation (NDE) techniques for composite overwrapped pressure vessels intended for gaseous hydrogen infrastructure applications. The majority of the study focuses on Model Acoustic Emissions (MAE) techniques. Testing was performed on various composite tank designs including small high pressure plastic-lined fully-wrapped composite pressure vessels designed for portable, stationary or vehicular storage and large steel-lined hoop-wrapped pressure vessels designed for bulk transport and stationary storage. MAE testing was performed by Digital Wave Corp. on vessels provided by Lincoln Composites and TransCanada. MAE testing of Lincoln Composites plastic-lined fully-wrapped 10,000 psi composite pressure vessels was performed at the Lincoln facilities in April Tank damage was simulated through drilled holes, membrane cuts and a drop test, and subsequent proof and burst testing was performed while monitoring with MAE techniques. The manufacturing consistency was confirmed by MAE. Generally, it was observed that the vessels failed at damage sites. Drilled holes all the way through the composite resulted in lowest burst pressure, followed by impact from 6-ft. drop onto concrete, and finally the cut fibers. MAE picked up the newly introduced damage very well on first pressurization after damage occurred. Emission did not completely stabilize, indicating that the damage did continue to grow during the pressure holds. At the higher sensitivity setting, MAE Frictional Emission (FRAE) was picked up on every cycle after damage. Location of damage was very clear acoustically using MAE techniques. MAE testing of six TransCanada large steel-lined hoop-wrapped composite pressure vessels was performed in October The test program included cyclic testing, pressure/autofrettage and burst testing while monitoring using MAE techniques. During cycle testing crack growth was detected in the metallic head to shell welds at both ends of the vessel. The number of cycles sustained before fatigue failure due to this cracking exceeded the required 10,000 cycles. This was determined from the acoustical signal produced by a leak source. During the pressure (autofrettage) tests, the cumulative events versus time curves showed a characteristic roll over during pressure load holds in the AE test in all cases. There were few or no events during the load holds and very few events during the AE test. This is consistent with fracture mechanics reasoning since the AE test pressure is so much lower than the autofrettage pressure. It was observed that autofrettage cycles at 1.5 x operating pressure instrumented for AE detection would bound an AE cycle at 1.1 x operating pressure. This conclusion is in agreement with previous experience on various other pressure vessels. A study and laboratory testing of MAE sensor arrays constructed of piezoelectric material, polyvinylidene film (PVDF), was performed by Digital Wave Corp. in February This study looked at two ways to enhance the sensitivity of the PVDF film transducers, 1) sensor stacking and analog summation of the sensor outputs, and 2) digital summation of the sensor outputs. It was observed that stacked sensors increased sensitivity of detection, there was no phase distortion due to stacking and reducing sensor size can reduce aperture affects and increase bandwidth. A phased array configuration for modal acoustic emission (MAE) can determine direction of source and possibly distance. Phasing of signals for source location is possible and aids in mode identification and source location, which is very sensitive to variations in arrival time differences. Sensor placement is also extremely important, and the sensitivity to array geometry must be studied. This report also includes additional discussion of other relevant NDE and analysis techniques including a study of composite tank hydrostatic test requirements, a finite element analysis (FEA) and fracture mechanics analysis on composite reinforced pressure vessels predicting failures observed during testing and indicated using AE techniques, and a discussion of photon induced positron annihilation (PIPA) which is a potential NDE process that can assess material damage at the near-molecular level 20

23 List and Status of Existing Regulations, Codes and Standards Publications Scope Rev. ASME STP-PT-023 Guidelines for In- Service Inspection of Composite Pressure Vessels This report describes the procedures and recommendations for in-service inspection of high pressure composite tanks made to ASME code requirements and used for the shipping or storage of hydrogen. Guidelines are given for acceptable methods of visual inspection of high pressure composite tanks and for acceptance criteria for any indications that are found by the visual inspection. 21