FINAL REPORT ON RCS INCLUDING PRELIMINARY ACTION PLAN

Transcription

1 DELIVERABLE 4.2 FINAL REPORT ON RCS INCLUDING PRELIMINARY ACTION PLAN * Regulations, Codes, and Standards FINAL Jean-Paul ANTONIOTTI Randy DEY Acknowledgement This project is co-financed by European funds from the Fuel Cells and Hydrogen Joint Undertaking under FCH-JU Grant Agreement Number The project partners would like to thank the EU for establishing the Fuel cells and hydrogen framework and or 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. 2

3 D4.2 : Final report on RCS including preliminary action plan CONTENTS 1 INTRODUCTION CATEGORIZATION OF CONTAINMENT SOLUTIONS EVOLUTION OF CONTAINERS CHARACTERISTICS RESULTING FROM THE IMPLEMENTATION OF COMPOSITE MATERIALS RCS LANDSCAPE Regulatory landscape Standards landscape ANALYSIS OF REGULATION AND STANDARDS Reference to standards ADR Definitions Relevant standards ADR referenced standards for cylinders and tubes Burst pressure ratio Periodic inspection Service life BARRIERS AND GAPS TO BE ADDRESSED IN RCS FRAMEWORK PRELIMINARY RESULTS APPENDIX 1:TRANSPORTABLE COMPOSITE HYDROGEN STORAGE - LIST OF PUBLISHED DOCUMENTS APPENDIX 2: TRANSPORTABLE COMPOSITE HYDROGEN STORAGE - LIST OF ACTIVE WORK APPENDIX 3 - REASONS PROVIDED BY BAM FOR THE NEED OF ATR D 3/10 AND ATD D 4/

4 D 4..2 : Final report on RCS including preliminary action plan 1 INTRODUCTION The first objective of this deliverable is to provide an analysis of the barriers that have to be lifted and the gaps that need to closed in the regulations, codes, and standards (RCS) framework to allow implementation of composite material based high pressure storage technology for the transport and delivery of compressed hydrogen to its full potential. Due to the strong link between regulation and standards in this activity, barriers and gaps need to be identified and addressed both in the regulation and in the standards framework in order to avoid unnecessary restrictions while ensuring the expected level of safety. The second objective is to suggest a preliminary action plan. 4

5 D4.2 : Final report on RCS including preliminary action plan 2 CATEGORIZATION OF CONTAINMENT SOLUTIONS For the applications considered in DeliverHy, compressed hydrogen is transported in transport units constituted of assemblies of individual pressure vessels. Depending on the quantities to be delivered, these assemblies are either a framed unit intended for handling and transportation as a package, or a road trailer for larger quantities. Different types of construction are used for the pressure vessels, categorized as follows: - Type 1: all metal cylindrical pressure vessel - Type 2: hoop wrapped cylindrical pressure vessel with a load sharing metal liner and composite reinforcement on the cylindrical part only - Type 3: fully wrapped cylindrical pressure vessel with a load sharing metal liner and composite reinforcement on both the cylindrical part and dome ends - Type 4: fully wrapped cylindrical pressure vessel with a non-load sharing liner and composite reinforcement on both the cylindrical part and the dome ends Two size categories are defined, - Cylinders: up to 150 l - Tubes: greater than 150 l (but limited to 3000 l, see below) Note: These limits are mainly a reflection of the volume ranges of the metallic (Type 1) cylinders and tubes used when the regulation was drafted. The scope of RCS requirements is mainly defined by reference to the - Type of assembly (e.g. bundle, trailer also called battery-vehicle) - Category of pressure vessel (cylinder, tube) - Construction type of pressure vessel (Type 1, Type 2, Type 3, Type 4) - Pressure vessel water capacity - Pressure vessel working pressure this is the pressure at which the pressure vessel is intended to be filled, assuming a settled gas temperature of 15 C. Consequently, the RCS limitations in terms of gaps or barriers to the implementation of technically relevant innovative solutions will appear in accordance with these characteristics. For instance, for a given type of assembly, only certain types of pressure vessels may be considered. Or there may be no reference for pressure vessels exceeding a certain water capacity limit. 5

6 D 4..2 : Final report on RCS including preliminary action plan 3 EVOLUTION OF CONTAINERS CHARACTERISTICS RESULTING FROM THE IMPLEMENTATION OF COMPOSITE MATERIALS The implementation of composite material technology, i.e. Type 3 and Type 4 constructions has led to the following evolution in pressure vessel characteristics: - increase of water capacity, as these constructions are not subject to the limitations on diameter inherent to Type 1 and Type 2 constructions - increase of design pressure, as these constructions are not subject to the manufacturability limitations on wall thickness inherent to Type 1 and Type 2 constructions. This has resulted in the implementation of assemblies having a set of characteristics not previously considered by the regulators, such as - Tubes with a capacity greater than the upper limit of l included in the regulatory definition of tubes. - Pressure vessels with a capacity greater than 150 l intended for constituting a standard cylinder assembly (called bundle) where the regulation only allows use of cylinders having by definition a capacity not greater than 150 l - Working pressure of 50 MPa or more, 6

7 D4.2 : Final report on RCS including preliminary action plan 4 RCS LANDSCAPE 4.1 Regulatory landscape Transport of dangerous goods needs to be regulated in order to prevent, as far as possible, accidents to persons or property and damage to the environment, the means of transport employed or to other goods. However, with different regulations in every country and for different modes of transport, international trade in chemicals and dangerous products would be seriously impeded, if not made impossible and unsafe. Moreover, dangerous goods are also subject to other kinds of regulations, e.g. work safety regulations, consumer protection regulations, storage regulations, environment protection regulations. In order to ensure consistency between all these regulatory systems, the United Nations has developed mechanisms for the harmonization of hazard classification criteria and hazard communication tools (GHS) as well as for transport conditions for all modes for transport (TDG). It is under this framework that the UN Recommendations on the Transport of Dangerous Goods, Model Regulations are developed under the auspices of the Sub- Committee of Experts on the Transport of Dangerous Goods (SCETDG). In addition, the United Nations Economic Commission for Europe (UNECE) administers regional agreements that ensure the effective implementation of these mechanisms as far as transport of dangerous goods by road, rail and inland waterways is concerned. It is in this context that 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 UNECE, 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 says 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. The structure is consistent with that of the UN Recommendations on the Transport of Dangerous Goods, Model Regulations, the International Maritime Dangerous Goods Code (of the International Maritime Organization), the Technical Instructions for the Safe Transport of Dangerous Goods by Air (of the International Civil Aviation Organization) and the Regulations concerning the International Carriage of Dangerous Goods by Rail (of the Intergovernmental Organisation for International Carriage by Rail). The ADR categorizes products in classes in function of their physical and chemical properties. 7

8 D 4..2 : Final report on RCS including preliminary action plan For the transport of products belonging to the class covering hydrogen, the technical requirements applying to the transportable containers are to a large extent defined by reference to international standards. Appendix 1 provides further details on this regulation. The applicable regulatory framework is that of the international regulation on the transport of dangerous goods by road (ADR). 4.2 Standards landscape The international standards providing the technical requirements applicable to the transportable units implemented for the transport of compressed hydrogen are developed by ISO/TC 58 Gas cylinders - SC3 Cylinder design. There are a number of standards addressing the different types of pressure vessels used and their assemblies. The published standards as well as those under development are listed in Appendixes 1 and 2. 8

9 D4.2 : Final report on RCS including preliminary action plan 5 ANALYSIS OF REGULATION AND STANDARDS 5.1 Reference to standards As indicated above, the regulation refers mainly to standards to define the applicable requirements for hydrogen containers. There are a number of standards addressing the different types of pressure vessels and types of constructions used, along with their various forms of assembly. The published standards as well as those under development are listed in Appendixes 1 and 2. The ADR provides the following definitions for the pressure vessels and forms of assembly potentially used for compressed hydrogen: 5.2 ADR Definitions ADR defines the following pressure vessel and assemblies relevant for the transportation of compressed hydrogen - Battery-vehicle: a vehicle containing elements which are linked to each other by a manifold and permanently fixed to a transport unit. The following elements are considered to be elements of a battery-vehicle: cylinders, tubes, bundles of cylinders (also known as frames), pressure drums as well as tanks destined for the carriage of gases as defined in with a capacity of more than 450 litres; - Bundle of cylinders: an assembly of cylinders that are fastened together and which are interconnected by a manifold and transported as a unit. The total water capacity shall not exceed litres except that bundles intended for the transport of gases of Division 2.3 shall be limited to litres water capacity; - Cylinder: a transportable pressure receptacle of a water capacity not exceeding 150 litres; - Multiple-element gas container (MEGC): a multimodal assembly of cylinders, tubes and bundles of cylinders which are interconnected by a manifold and which are assembled within a framework. The MEGC includes service equipment and structural equipment necessary for the transport of gases; - Pressure receptacle: collective term that includes cylinders, tubes,[ pressure drums, closed cryogenic receptacles, metal hydride storage system,] bundles of cylinders [and salvage pressure receptacles]; - Tube: a seamless transportable pressure receptacle of a water capacity exceeding 150 litres but not more than litres; Note : The designation seamless, intended to exclude welded constructions, does not exclude Type 3 and Type 4 constructions. This is confirmed by the fact clause mentions tubes in composite material: Pressure receptacles in composite materials For composite cylinders, tubes, pressure drums and bundles of cylinders which make use of composite materials, the construction shall be such that... 9

10 D 4..2 : Final report on RCS including preliminary action plan The set of assemblies used for hydrogen covered by the ADR and that are allowed to be transported on the roads of the participating countries are therefore in practice those covered by referenced standards. However there are some complications explained hereafter that interfere with the practical application of the above principle: - The definition of cylinders in standards and the ADR is not the same - UN-receptacles (approved for international transport, designed according to an ISO standard) and Non-UN receptacles (such as those approved according to an EN standard and Pi marked) are handled somewhat differently as far as definition of referenced standards is concerned - There is typically a significant lapse of time of a few years between the publication of a standard and the entry into force of the revised ADR referencing this standard. 5.3 Relevant standards Table 1 below provides the range of relevant pressure vessel and assembly characteristics currently covered by published standards, with their status in the ADR. Standard reference ADR version Pressure vessel category (ADR) and construction types Scope of standard* Scope of standard Water volume Working pressure (@ 15 C)(2/3 of Ph) EN 12245: Cylinders, Types 2, 3, 4, Up to l No limit specified + A1:2011 and 5 (no liner) ISO 11120: Tubes, in steel (Type 1) Greater than 150 l up to l No limit specified ISO : Cylinders, Type 2 Up to 450 l No limit specified ISO : Cylinders, Type 3 Up to 450 l No limit specified ISO/FDIS Cylinders, Type 4 Up to 450 l No limit specified ISO/CD Not yet scheduled Tubes, [Types 3 and] 4 - Permanently mounted in a frame From 450 l, up to [100 MPa] l [addition of elements in brackets to scope is currently being proposed] ISO Not yet scheduled Tubes type 2, 3 and 4 Greater than 450 l, up to 3,000 l MPa 10

11 D4.2 : Final report on RCS including preliminary action plan *May differ from scope of application of the standard in ADR. Note: The status of standards changes often. The above list only reflects status available at the time this report was prepared. Table 1 Relevant standards 5.4 ADR referenced standards for cylinders and tubes UN pressure receptacles are covered by section Requirements for UN pressure receptacles which specify the applicable referenced standards for cylinders ( ) on the one hand and tubes ( ) on the other hand. The ISO standards listed in the table 1, although they include tubes with a water capacity of up to 450L, are only included in the clause providing referenced standards for cylinders ( ). As a result tubes complying with ISO X standards are not covered today by ADR, and there is therefore, at the moment, no referenced standards applicable to UN tubes in composite materials (i.e. designed according to ISO standards.) in ADR. For non-un pressure receptacles designed, constructed and tested according to referenced standards, covered by section , the referenced standards applicable to cylinders and tubes are covered together by a single clause. It is hence sufficient for non-iso referenced standards to cover tubes for these to be applicable to such tubes in ADR. It can be observed that according to this analysis, it is already possible to implement MEGC s and battery vehicles constituted of composite pressure vessels with a capacity of up to 450 l, without any limit on pressure, simply by applying referenced standard EN 12245:2002. Note: Justification of German regulation ATR D 3/10 and ATR D 4/10 The reasons which led Germany to develop a specific regulation for covering tube trailers made up of pressure vessels of up to 450 l and a working pressure of 500 bar are explained by BAM in a note shown in Appendix 3. However the justification provided is not too clear. 11

12 D 4..2 : Final report on RCS including preliminary action plan 5.5 Burst pressure ratio The section describing the requirements applicable to pressure vessels is organised as follows: Requirements for UN pressure receptacles General requirements for non-un pressure receptacle Requirements for non-un pressure receptacles designed, constructed and tested according to referenced standards Requirements for non-un pressure receptacles not designed, constructed and tested according to referenced standards The ADR specifies a burst pressure ratio only for non-un pressure receptacles not designed, constructed and tested according to referenced standards covered by as specified in : Pressure receptacles in composite materials For composite cylinders, tubes, pressure drums and bundles of cylinders which make use of composite materials, the construction shall be such that a minimum burst ratio (burst pressure divided by test pressure) is: for hoop wrapped pressure receptacles; for fully wrapped pressure receptacles. For other types of pressure receptacles - i.e. UN pressure receptacles (6.2.2) on the one hand, and Non-UN pressure receptacles designed, constructed and tested according to referenced standards (6.2.3 and 6.2.4), on the other hand, the burst pressure ratio to be applied is specified in the referenced standards. The burst ratio is currently a fixed value for all cylinders developed in composite material. Due to the different characteristics and specially the COV (Coefficient of Variation), it is better to justify an unfixed value. Each supplier will have to justify the correct burst ratio providing test results + justification of the COV 5.6 Periodic inspection Regarding periodic inspection and testing, For UN composite pressure vessels: ADR requires EN ISO 11623:2002 to be applied for cylinders. No requirement is provided for tubes, nor is there any clause making the use of a referenced standard mandatory. 12

13 D4.2 : Final report on RCS including preliminary action plan For non-un composite pressure vessels: ADR makes the use of a referenced standard mandatory and requires of EN ISO 11623:2002 to be applied (except clause 4) Furthermore, for pressure vessels in composite material, ADR refers to the competent authority for defining periodic inspection frequencies as follows: In P200 packing instructions, cl. 2) d) includes the following: NOTE: For pressure receptacles which make use of composite materials, the periodic inspection frequencies shall be as determined by the competent authority which approved the receptacles. Additionally, it is to be noted that the UN committee (SCETDG) in charge of proposing revisions of the model regulation (see 4.1) agreed in November 2012 to request the revision of the above Note as follows: NOTE: For pressure receptacles which make use of composite materials, the maximum test period shall be 5 years. The test period may be extended to that specified in Table 1 (i.e. up to 10 years), if approved by the competent authority of the country of use. Important comment: The adoption of this revision is likely to encourage the imposition by national authorities of specific methods in function of the test period requested. 5.7 Service life For pressure vessels in composite material, ADR also refers to the competent authority for defining service life as follows: In ADR includes the following (see note2) UN cylinders, except that inspection requirements related to the conformity assessment system and approval shall be in accordance with : ISO :2002 ISO :2002 ISO :2002 Gas cylinders of composite construction Specification and test methods Part 1: Hoop wrapped composite gas cylinders Gas cylinders of composite construction Specification and test methods Part 2: Fully wrapped fibre reinforced composite gas cylinders with load-sharing metal liners Gas cylinders of composite construction Specification and test methods Part 3: Fully wrapped fibre reinforced composite gas cylinders with non-load-sharing metallic or non-metallic liners 13

14 D 4..2 : Final report on RCS including preliminary action plan NOTE 1: In the above referenced standards composite cylinders shall be designed for unlimited service life. NOTE 2: After the first 15 years of service, composite cylinders manufactured according to these standards, may be approved for extended service by the competent authority which was responsible for the original approval of the cylinders and which will base its decision on the test information supplied by the manufacturer or owner or user. It is to be noted that the UN committee (SCETDG) in charge of proposing revisions of the model regulation (see 4.1) agreed in November 2012 to request the revision of the above Note 2 as follows: NOTE 2: The service life of a composite cylinder shall not be extended beyond its initial approved design life. Regardless of the cylinder design life, composite cylinders shall not be filled after 15 years from the date of manufacture, unless the design has successfully passed a service life test programme. The programme shall be part of the initial design type approval and shall specify inspections and tests to demonstrate that cylinders manufactured accordingly remain safe to the end of their design life..the service life test programme and the results shall be approved by the competent authority that was responsible for the initial approval of the cylinder design. Important comment: The notion behind this note that it is up to the competent authority to define the additional tests required to allow use beyond 15 years is questionable. Such requirements should be part of the applicable standard covering design and manufacturing. 14

15 D4.2 : Final report on RCS including preliminary action plan 6 BARRIERS AND GAPS TO BE ADDRESSED IN RCS FRAMEWORK PRELIMINARY RESULTS To implement MEGC s or battery vehicles constituted of pressure vessels (cylinders or tubes) with a water capacity ranging from 50l to l (or 10,000 l if risk analysis is provided that justifies that this volume will reduce the risk due to the use of less tubing or fewer valves) and a nominal fill pressure exceeding 50 MPa, meeting improved (optimized) design requirements, for instance with regards to the burst pressure ratio, this analysis leads to the preliminary conclusions that the following is required : - 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 extend the definition of tubes to cover the frame mounted tubes having a water capacity from 450 l up to l covered by ISO (if we can justify by risk analysis for this value), - 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, (if we can justify by risk analysis for this value). - Need to have inspection requirements for composite vessels determined only from requirements specified through ADR, - 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. 15

16 D 4..2 : Final report on RCS including preliminary action plan APPENDIX 1:TRANSPORTABLE COMPOSITE HYDROGEN 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. 16

17 D4.2 : Final report on RCS including preliminary action plan 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 seagoing 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. 17

18 D 4..2 : Final report on RCS including preliminary action plan Publications Scope Rev. European Agreement concerning the International Carriage of Dangerous Goods by Road (ADR) 2011 Recognized technical code (Anerkanntes Technisches Regelwerk, ATR) for the construction, equipment, test, approval, an requirements should be part of the applicable standard covering design and manufacturing d marking as transportable pressure equipment of composite tubes with a seamless, load sharing aluminium liner and a working pressure not exceeding 500 bar and a water capacity not exceeding 450 L (ATR D 3/10) Recognized technical code (Anerkanntes Technisches Regelwerk, ATR) for the construction, equipment, test, approval, and marking as transportable pressure equipment of composite tubes with a non-load sharing plastics liner with a working pressurenot exceeding 500 bar and a water capacity not exceeding 450 L (ATR D 4/10) 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 2013, a revised consolidated version has been published as document ECE/TRANS/225, Vol. I and II- This German regulation applies to the construction, equipment, test, approval and marking of composite tubes up to a maximum working pressure of 50 MPa and a water capacity of not more than 450 litres which have a seamless aluminium liner which is reinforced by a wound composite consisting of carbon fibres embedded in a matrix. This standard specifies the requirements for periodic inspection and testing of hoop wrapped and fully wrapped composite transportable gas cylinders, with aluminium, steel or non-metallic liners or of linerless construction, intended for compressed, liquefied or dissolved gases under pressure, of water capacity from 0,5 l up to 450 l. NOTE As far as practicable, this standard may also be applied to cylinders of less than 0,5 l water capacity. This standard specifies the requirements for periodic inspection and testing to verify the integrity of such gas cylinders for further service. This German regulation applies to the construction, equipment, test, approval, and marking as transportable pressure equipment of composite tubes with a non-load sharing plastics liner with a working pressure not exceeding 500 bar and a water capacity not exceeding

19 D4.2 : Final report on RCS including preliminary action plan Publications Scope Rev. EN 12245:2002 EN 12245:2009 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 La présente norme spécifie les exigences minimales relatives aux matériaux, à la conception, à la construction, aux essais de qualification de modèle et aux contrôles courants de production, des bouteilles à gaz composites, d'une contenance en eau inférieure ou égale à 450 l, pour gaz comprimés, liquéfiés et dissous. NOTE Pour les besoins de la présente norme, le mot «bouteille» englobe les tubes d une contenance en eau inférieure ou égale à 450 l. La présente norme s'applique aux bouteilles constituées d'un liner métallique (avec ou sans soudure), ou non métallique (ou constitué d'un mélange de ces matériaux), renforcé par un enroulement composite en fibres de verre, de carbone ou d'aramide (ou un mélange de ces matériaux) noyées dans une matrice. La présente norme s'applique également aux bouteilles à gaz en composite sans liner. La présente norme ne s'applique pas aux bouteilles à gaz partiellement recouvertes de fibres et couramment appelées «bouteilles frettées». Pour les bouteilles frettées composite, voir l EN NOTE Cette spécification ne traite pas de la conception, du montage et des performances des gaines de protection amovibles. Lorsque celles-ci sont montées, il convient de les considérer séparément. La présente Norme européenne spécifie les exigences minimales relatives aux matériaux, à la conception, à la construction, aux essais de qualification de modèle et aux contrôles courants de production, des bouteilles à gaz en matériaux composites pour gaz comprimés, liquéfiés et dissous. NOTE 1 Pour les besoins de la présente Norme européenne, le mot «bouteille» englobe les tubes (conteneurs sous pression transportables d une capacité en eau supérieure à 150 litres mais non supérieure à litres). La présente Norme européenne s'applique aux bouteilles constituées d'un liner métallique (avec ou sans soudure),ou non métallique (ou constitué d'un mélange de ces matériaux), renforcé par un enroulement composite en fibres de verre, de carbone ou d'aramide (ou un mélange de ces matériaux) noyées dans une matrice. La présente Norme européenne s'applique également aux bouteilles à gaz en composite sans liner. La présente Norme européenne ne s'applique pas aux bouteilles à gaz partiellement recouvertes de fibres et couramment appelées «bouteilles frettées». Pour les bouteilles frettées en matériaux composites, voir l EN NOTE 2 La présente Norme européenne ne traite pas de la conception, du montage et des performances des gaines de protection amovibles. Lorsque celles-ci sont montées, il convient de les considérer séparément. La présente Norme européenne concerne principalement les gaz industriels autres que le GPL mais elle peut également s appliquer au GPL. NOTE 3 Pour les bouteilles à GPL, voir l EN 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. 19

20 D 4..2 : Final report on RCS including preliminary action plan Publications Scope Rev. 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 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 :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). 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 over-wrapped 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 non-limited 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 over-wrapped 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 load-sharing 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, 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. 20

21 D4.2 : Final report on RCS including preliminary action plan Publications Scope Rev. 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 19078:2006 Gas cylinders -- Inspection of the cylinder installation, and requalification of high pressure cylinders for the on-board 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 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 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. 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. This standard specifies the requirements for periodic inspection and testing of hoop wrapped and fully wrapped composite transportable gas cylinders, with aluminium, steel or non-metallic liners or of linerless construction, intended for compressed, liquefied or dissolved gases under pressure, of water capacity from 0,5 l up to 450 l. NOTE As far as practicable, this standard may also be applied to cylinders of less than 0,5 l water capacity. This standard specifies the requirements for periodic inspection and testing to verify the integrity of such gas cylinders for further service. 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. 21

22 D 4..2 : Final report on RCS including preliminary action plan Publications Scope Rev. ASME STP-PT-003 Hydrogen Standardization Interim for Tanks, Piping, and Pipelines ASME STP-PT-004 Impregnated Graphite for Pressure Vessels ASME STP-PT-005 Design Factor Guidelines for High-Pressure Composite Hydrogen Tanks 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. 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. 22

23 D4.2 : Final report on RCS including preliminary action plan Publications Scope Rev. ASME STP-PT-014 Data Supporting Composite Tank Standards Development for Hydrogen Infrastructure Applications 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. 23

24 D 4..2 : Final report on RCS including preliminary action plan 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 compositereinforced 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 pre-loaded 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 thin-walled 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 long-term 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. 24