STP-PT-014

DATA SUPPORTING COMPOSITE TANK STANDARDS DEVELOPMENT

FOR HYDROGEN INFRASTRUCTURE APPLICATIONS

STP-PT-014

DATA SUPPORTING COMPOSITE TANK STANDARDS DEVELOPMENT

FOR HYDROGEN INFRASTRUCTURE APPLICATIONS

Prepared by:

Norman L. Newhouse, Ph.D., P.E. Lincoln Composites

Craig Webster, P. Eng.

Powertech Labs

Date of Issuance: February 10, 2008

This report was prepared as an account of work sponsored by National Renewable Energy Laboratory (NREL) and the ASME Standards Technology, LLC (ASME ST-LLC).

Neither ASME, ASME ST-LLC, NREL, Lincoln Composites and Powertech Labs, nor others involved in the preparation or review of this report, nor any of their respective employees, members, or persons acting on their behalf, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe upon privately owned rights.

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ISBN No. 0-7918-3142-6

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All Rights Reserved

Data Supporting Composite Tank Standards Development STP-PT-014

TABLE OF CONTENTS

FOREWORD v

ABSTRACT vi

1. HISTORY OF SAFETY EXPERIENCE OF COMPOSITE PRESSURE VESSELS 1

   1. Aerospace/Defense Use of Composite Pressure Vessels 1

      1. Applications 1

      2. Materials 1

      3. Standards 2

      4. Field service 2

   2. Commercial use of Composite Cylinders 2

      1. Applications 2

      2. Materials 3

      3. Standards 3

      4. Field Service 4

   3. Composite Containers for Natural Gas and Hydrogen Vehicle Applications 4

      1. Applications 4

      2. Cylinder Construction 5

      3. Materials 6

      4. Standards 7

      5. Field Service 8

2. DEVELOPMENT OF ASME AND OTHER STANDARDS 13

   1. Background Data Supports Standards Development. 13

   2. Performance vs. Design Standards 13

      1. General Issues 13

      2. Safety Factors 14

   3. Testing to Validate Requirements 17

      1. FMEA Approach to Validation Testing 17

      2. Materials Testing 17

      3. Cylinder testing 20

   4. Batch and Acceptance Testing 30

3. RECOMMENDATIONS FOR FATIGUE TESTING 33

   1. ASME Section VIII Division 3, Para KD-1260 Approach 33

   2. Composite Cyclic Fatigue 33

   3. Liner Cyclic Fatigue 35

   4. Composite vs. Liner Fatigue Limits 36

4. STRESS RUPTURE TESTING 37

   1. Stress Rupture Studies 37

   2. Field Testing and Experience 39

   3. Methods for Accelerating Tests and Extrapolating Data 40

5. SUMMARY AND RECOMMENDATIONS 42

REFERENCES 43

ANNEX A MATERIAL TEST PROCEDURES 46

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STP-PT-014 Data Supporting Composite Tank Standards Development

ANNEX B CYLINDER QUALIFICATION TEST PROCEDURES 49

ANNEX C BATCH TESTS 55

FIGURES 56

ACKNOWLEDGMENTS 61

ABBREVIATIONS AND ACRONYMS 62

LIST OF TABLES

Table 1 - Typical Fiber Properties 6

Table 2 - Field Failures 9

Table 3 - Fiber Stress Ratios 15

Table 4 - Recommended Material Testing 19

Table 5 - Recommended Cylinder Qualification Testing 28

Table 6 - Qualification for Design Changes 29

Table 7 - Recommended Batch Testing 32

LIST OF FIGURES

Figure 1 - Composite Cyclic Fatigue Lives 34

Figure 2 - Carbon Composite Fatigue Life vs. Load Level 35

Figure 3 - Glass Composite Strand Stress Rupture Design Chart 37

Figure 4 - Maximum Likelihood Estimates of Lifetimes of Aramid/Epoxy for Vessels, with

Quantile Probabilities 38

Figure 5 - Carbon Composite Strand Stress Rupture Design Chart 39

Figure 6 - All-composite fuel tank impacted by bridge (front view) 56

Figure 7 - All-Composite Fuel Tank Impacted by Bridge (top view) 56

Figure 8 - All-Composite Fuel Tank Impacted by Curb 57

Figure 9 - All-Composite Fuel Tank Dropped from Vehicle 57

Figure 10 - All-Composite Tank with Embedded Debris 58

Figure 11 - Hijacked NGV Bus. 58

Figure 12 - Bus with Fire in Engine Compartment 59

Figure 13 - NGV Bus with Fire Damage 59

Figure 14 - All-Composite Fuel Containers that are Roof Mounted in Buses 60

Figure 15 - All-Composite Fuel Containers that are Floor Mounted on Buses 60

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Data Supporting Composite Tank Standards Development STP-PT-014

FOREWORD

Commercialization of hydrogen fuel cells, in particular fuel cell vehicles, will require development of an extensive hydrogen infrastructure comparable to that which exists today for petroleum. This infrastructure must include the means to safely and efficiently generate, transport, distribute, store and use hydrogen as a fuel. Standardization of pressure retaining components, such as tanks, piping and pipelines, will enable hydrogen infrastructure development by establishing confidence in the technical integrity of products.

Since 1884, the American Society of Mechanical Engineers (ASME) has been developing codes and standards (C&S) that protect public health and safety. The traditional approach to standards development involved writing prescriptive standards only after technology has been established and commercialized. With the push toward a hydrogen economy, ASME has adopted a more anticipatory approach to standardization for hydrogen infrastructure which involves writing standards with more performance based requirements in parallel with technology development and before commercialization has begun.

The ASME B&PVC Standards Committee appointed a project team to develop new Code rules in the for hydrogen storage and transport tanks to be used in the storage and transport of liquid and gaseous hydrogen and metal hydrides. Rules for gaseous storage tanks with maximum allowable working pressures (MAWPs) up to 15,000 psig (100 MPa) will be needed. Research activities are being coordinated to develop data and technical reports concurrent with standards development and have been prioritized per Project Team needs. This Technical Report has been developed in response to Project Team needs and is intended to establish data and other information supporting separate initiatives to develop ASME standards for the hydrogen infrastructure.

Established in 1880, the American Society of Mechanical Engineers (ASME) is a professional not- for-profit organization with more than 127,000 members promoting the art, science and practice of mechanical and multidisciplinary engineering and allied sciences. ASME develops codes and standards that enhance public safety, and provides lifelong learning and technical exchange opportunities benefiting the engineering and technology community. Visit www.asme.org for more information.

The ASME Standards Technology, LLC (ASME ST-LLC) is a not-for-profit Limited Liability Company, with ASME as the sole member, formed in 2004 to carry out work related to newly commercialized technology. The ASME ST-LLC mission includes meeting the needs of industry and government by providing new standards-related products and services, which advance the application of emerging and newly commercialized science and technology and providing the research and technology development needed to establish and maintain the technical relevance of codes and standards. Visit www.stllc.asme.org for more information.

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STP-PT-014 Data Supporting Composite Tank Standards Development

ABSTRACT

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.

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