STP/PT-003

HYDROGEN STANDARDIZATION INTERIM REPORT

For

Tanks, Piping, and Pipelines

STP/PT-003

HYDROGEN STANDARDIZATION INTERIM REPORT

for

Tanks, Piping, and Pipelines

Date of Issuance: June 6, 2005

This report was prepared as an account of work sponsored by the National Renewable Energy Laboratory (NREL) and the American Society of Mechanical Engineers (ASME).

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TABLE OF CONTENTS

FOREWORD x

ABSTRACT xii

PART I - Review of Existing Reference Standards to Support New Code Rules for High-Pressure Hydrogen Vessels 1

1. INTRODUCTION 2

   1. General Background of Code Work for 15,000 psi Hydrogen Vessels 2

   2. Reference Standards 3

   3. Steel Cylinder Designs 3

   4. Composite Cylinder Designs 4

   5. Stationary Storage Vessels 4

   6. Performance Based vs. Prescriptive Standards 5

   7. Reference Performance Based Standards 5

   8. Potential for a New Performance Code 6

   9. Performance Standards Dependent on Design Calculations 6

   10. Potential Design Code for Hoop-Wrapped Vessels 6

   11. Potential for a Full-Composite Cylinder Design Code 7

2. COMPARISON OF OPERATING MARGINS FOR EXISTING STANDARDS 9

   1. Operating Margin Definition 9

   2. Maximum Normal Operating Pressure (MNOP) 9

   3. ASME Design Pressure and MNOP 9

   4. MNOP for Non-Code Reference Standards 10

   5. MNOP by Vessel Usage 10

      1. ASME Storage Vessel MNOP 10

      2. DOT Compressed Gas Cylinder MNOP 10

      3. MNOP for ISO Gas Cylinders 11

      4. MNOP for Vehicle Fuel Containers 11

   6. Normal Operating Pressure (NOP) 12

   7. Maximum Pressure During Upsets or Fire Exposure 12

   8. Burst Pressure 13

      1. Burst Pressure of Composite Cylinders and Vessels 13

      2. Burst Pressure of Metal Cylinders and Vessels 14

      3. Burst Pressure for DOT Metal Gas Cylinders 16

   9. Burst Pressure of ISO Metal Gas Cylinders 17

   10. Summary of Margin Definitions 17

   11. Composite Stress Ratio Margins for Composites 17

       1. DOT-3AA Specification Margin 17

       2. DOT-3AA Margins Further Reduced 18

   12. Findings from Comparison of Margins between Different Standards 18

   13. Conclusions from Comparison of Margins 20

       1. DOT FRP-1 Anomaly 20

       2. Selection of Calculated over Design Margins for Metal Designs 20

       3. Primary Factors Affecting Margins 21

   14. Summary of Comparative Margins 23

       1. ASME Code Vessels 23

       2. Gas Cylinders for Transportation 23

       3. Gas Cylinders for Vehicle Fuel Tanks 23

3. MANUFACTURING AND IN-SERVICE INSPECTION AND TEST PRACTICES IMPACTING MARGINS 24

   1. Review of Existing Inspection 24

   2. Review of Existing Inspection Techniques for Metal Cylinders 24

   3. Review of Existing Inspection Techniques for Composite Cylinders 27

   4. Applicability and Limitations of Various NDE Techniques to Specific Vessels 28

   5. Metal Monobloc or Layered Vessels of Steel or Nonmagnetic Alloys 29

   6. Composite Hoop-Wrapped Vessels with Seamless or Welded Liners of Steel or

      Nonmagnetic Alloys 30

   7. Composite Full-Wrapped Vessels with Seamless or Welded Liners of Steel or

      Nonmagnetic Alloys 31

   8. Composite Full-Wrapped Vessels with Seamless or Welded Nonmetallic Liners and

      Metal Bosses of Steel or Nonmagnetic Alloys 31

   9. Overall Recommendations 32

   10. Recommendations for Inspection of All-Metal Cylinders at Manufacture 33

   11. Recommendations for In-service Inspection of All-Metal Cylinders 33

   12. Recommendations for Inspection of Composite Cylinders at Manufacture 34

   13. Recommendations for In-service Inspection of Composite Cylinders 34

4. RECOMMENDED MARGINS FOR NEW CODE RULES 36

   1. Factors Not Addressed by Margin to Burst 36

      1. Pressure Control 36

      2. Material Degradation 37

      3. Cyclic Fatigue 37

      4. Fire Exposure 37

      5. Impact Damage to Composites 37

   2. Minimum Recommended Gas Cylinder Margins for Materials Not Susceptible to Creep, Stress Rupture, or External Impact Induced Fracture (Metals) 38

   3. Minimum Gas Cylinder Margins for Materials Susceptible to Creep, Stress Rupture, or Impact Induced Fracture (Composite Reinforced Cylinders) 38

      1. Design of Composite Cylinders 38

      2. Recommended Margins for Types 3 and 4 Full-Wrapped Metal-Lined Designs

         Using Glass or Aramid Composite 41

      3. Recommended Margins for Type 2 Hoop-Wrapped Designs 42

      4. Recommended Margins for Type 3 and 4 Carbon Composite Vessels 44

      5. Burst Design Margins for Carbon Composite Designs 44

5. REQUIREMENT FOR SEPARATE DESIGN MARGINS FOR FATIGUE 50

   1. ASME Code Fatigue Rules 50

   2. DOT Composite Fatigue Margins 50

   3. DOT-3AA Metal Fatigue Margins 51

   4. NGV2 Fatigue Design Rules 52

   5. ISO Fuel Cylinder Fatigue Design Rules 53

   6. ISO Metal Gas Cylinder Design Rules 53

   7. ISO Composite Gas Cylinder Fatigue Design Rules 54

   8. ASME Code Case 2390-1 Fatigue Design Rules 54

6. EVALUATION OF MARGINS FOR 15,000 PSI METAL AND COMPOSITE VESSELS 56

   1. Use of Reference Standards 56

   2. Design Pressure Requirements 56

   3. Design for 15,000 psi Metal Vessels 56

      1. ASME Minimum Burst Margin 56

      2. Critical Difference in High Pressure Design 57

      3. Effect of Design Pressure on Recommended Minimum Margin 57

      4. Extrapolation of Reference Standards to 15,000 psi Operating Pressure 57

      5. Wall Thickness of Ductile Metal Vessels for 15,000 psi Operating Pressure 58

      6. Wall Thickness Concerns for Vessels Operating at 15,000 psi 60

      7. Critical Conditions for Safe Application of Low Margins at 15,000 psi 61

   4. Design for 15,000 psi Composite Reinforced Vessels 63

      1. Potential Advantages of Composite Vessels for 15,000 psi 63

      2. Potential Disadvantages of Composites for 15,000 psi 64

7. REVIEW OF SCOPE, LIMITATIONS AND MODIFICATION OF EXISTING STANDARDS FOR LARGE AND SMALL 15,000-PSI VESSELS 66

   1. Intended Scope of Modified Standards 66

   2. NOP or Service Pressure of New Hydrogen Transport Cylinders 66

   3. Scope, Limitation, and Modifications for Ductile Metal 15,000-psi Vessels 67

      1. Inspection and Test Requirements 67

      2. ASME Section VIII Division 3 67

      3. DOT-3AA/3AAX and ISO 9809/11120 Metal Gas Cylinder Standards 68

   4. Scope, Limitation, and Modifications for Composite Vessels 70

      1. Designs for Code Composite Reinforced Vessels 70

      2. Composite Material Characteristics and the Applicability of Metal Design Controls and Experience 71

      3. Composite Design 72

      4. Composite Durability 72

      5. Developed Strength of Composites 73

      6. Performance Tests Relative to Composite Stress Ratios 73

      7. Translation 73

      8. Stress Rupture of Carbon Composites 74

      9. Design Qualification by Similarity 74

      10. Resistance to Fracture of Carbon Composite Vessels 75

      11. Inspection Capability for Carbon Composite Cylinders 76

8. REVIEW OF EXISTING COMPOSITE CYLINDER STANDARDS FOR APPLICABILITY

   TO HYDROGEN STORAGE AT 15,000 PSI 77

   1. Scope of Review 77

   2. Requirements of Existing Composite Cylinder Standards and the Applicability to 15,000-

      psi Hydrogen Storage Vessels or Cylinders 77

      1. General Requirements of Existing Composite Cylinders 77

      2. Specific Present Composite Cylinder Standards 78

   3. Review of Existing Standards for Composite Cylinders for Specific Applicability to

      15,000 psi Hydrogen Storage Vessels 85

      1. Scope of New Vessels 85

      2. Scope of Present Composite Standards 85

      3. Specific Present Composite Cylinder Standards 86

   4. Review of Existing Standards for Composite Cylinders for Applicability to 15,000 psi Portable Hydrogen Cylinders 88

      1. Scope of New Cylinders 88

      2. Scope of Present Standards 88

      3. Scope Issues with DOT FRP-1 and FRP-2 Cylinders 88

      4. DOT CFFC 88

      5. ISO Composite Gas Cylinder Standards 89

         8.4.6 NGV2 89

         1. ISO 11439 CNG Fuel Cylinders 89

         2. ISO DIS 15869 Draft Standard for Hydrogen Vehicle Fuel Cylinders 89

         3. ASME Code Case 2390 90

9. NECESSARY VESSEL INSTALLATION CODES 91

References - PART I 93

PART II - A Study of Existing Data, Standards, and Materials Related to Hydrogen Service

(Storage and Transport Vessels) 97

1. INTRODUCTION 98

   1. Background 98

   2. Scope of Report 98

   3. Service Conditions 98

   4. Executive Summary 98

2. ISSUES RELATED TO USING EXISTING STANDARDS FOR HIGH-PRESSURE

   VESSELS 100

   1. Metallic Vessels 100

      1. Design Issues 101

      2. Manufacturing Issues 106

      3. Testing Issues 107

   2. Composite Vessels 112

      1. Design Issues 112

      2. Manufacturing Issues 112

      3. Testing Issues 112

3. SUCCESSFUL SERVICE DATA OF EXISTING VESSELS 120

   1. Storage Vessels 120

   2. Transport Tanks 120

   3. Portable Cylinders 120

   4. Vehicle Fuel Tanks 120

4. EFFECT OF HIGH-PRESSURE HYDROGEN ON EXISTING COMMONLY USED MATERIALS 121

   1. Existing Commonly Used Vessel Materials 121

   2. High-Pressure Hydrogen Exposure Degradation 121

      1. Types of Hydrogen Embrittlement 121

      2. Metallurgical and Process Factors Affecting Hydrogen Embrittlement 122

   3. Hydrogen Embrittlement Literature Review 122

   4. Recommended Metallic Materials For High-Pressure Hydrogen Service 131

      1. Basis of Recommendations for Aluminum, Copper, Titanium, Nickel, and Stainless Steel Alloys 131

      2. Basis of Recommendations for Carbon and Alloy Steels 131

5. SUMMARY AND RECOMMENDATIONS 134

References - PART II 136

Appendix A - Metallic Vessel Service Data 138

Appendix B - Composite Vessel Service Data 142

PART III - A Study of Existing Data, Standards and Materials Related to Hydrogen Service for Piping Systems and Transport Pipelines 147

1. INTRODUCTION 148

   1. Background 148

   2. Scope of Report 148

   3. Service Conditions 148

   4. Executive Summary 148

2. EXISTING DESIGN PHILOSOPHY/EXPERIENCE 150

   1. Piping Design Philosophy 150

      2.1.1 ASME B31.1 150

      2.1.2 ASME B31.3 151

   2. Pipeline Design Philosophy 154

      2.2.1 ASME B31.8 154

      1. DOT Standard CFR Title 49 Part 192 154

      2. Summary of Piping And Pipeline Standards 155

   3. Piping Experience and Data 156

1. Design Criteria 156

2. Service Data 156

3. In-Service Inspection and Safety 156

1. Pipeline Experience and Data 157

   1. Design Criteria 157

   2. Service Data 157

   3. In-Service Inspection and Safety 157

1. EFFECT OF HYDROGEN ON COMMON MATERIALS 158

   1. High-Pressure Hydrogen Exposure Degradation 158

      1. Types of Hydrogen Embrittlement 158

      2. Metallurgical and Process Factors Affecting Hydrogen Embrittlement 159

   2. Hydrogen Embrittlement Literature Review 159

   3. Recommended Metallic Materials For High-Pressure Hydrogen Service 168

      1. Basis of Recommendations for Aluminum, Copper, Titanium, Nickel and Stainless Steel Alloys 168

      2. Basis of Recommendations for Carbon and Alloy Steels 168

2. FACTORS UNIQUE TO HIGH-PRESSURE HYDROGEN SERVICE 171

   1. Surface Condition/Finish 171

   2. Bending of Piping And Tubing 172

      1. Cold Bending 172

      2. Hot Bending 173

   3. Piping Joints 174

      1. Welded Joints 174

      2. Mechanical Joints 176

      3. Dissimilar Metals 178

3. DESIGN AND MATERIAL SELECTION RECOMMENDATIONS FOR HYDROGEN SERVICE 179

   1. Piping Recommendations 179

      1. Material 179

      2. Design Margin 180

      3. Fatigue Life 180

      4. Leak Before Burst (LBB) 180

      5. Welding and Welded Pipes 181

      6. Pipe Fittings/Connections 181

      7. Autofrettage 181

   2. Pipeline Recommendations 181

      1. Pressure Limit 181

      2. Design Margin 181

      3. General Design Rules 182

      4. Material 182

References - PART III 183

Appendix A - Design Margins and Pressure Ratios 185

Appendix B - Mechanical Joint Information 189

Appendix C - Piping System Data 193

Appendix D - Pipeline Data 196

ACKNOWLEDGMENTS 203

ABBREVIATIONS AND ACRONYMS 204

List of Tables

Table 1 - Margin Comparison for Various Gas Cylinder and Vessel Standards 19

Table 2 - Requalification of Cylinders According to 48 CFR 180.209 25

Table 3 - Inspection Standards for All-Metal Cylinders Used in Hydrogen Service 27

Table 4 - UT Inspection Requirements at Manufacture for Metal Cylinders 27

Table 5 - Summary of Advantages and Limitations of Inspection Techniques for All-Metal

Cylinders 29

Table 6 - Summary of Advantages and Limitations of Inspection Techniques for Hoop-Wrapped Cylinders 31

Table 7 - Summary of Advantages and Limitations of Inspection Techniques for All-Composite Cylinders 32

Table 8 - Comparison of Fully Metallic Standards 109

Table 9 - Comparison of Composite Standards 116

Table 10 - Results of Tests in 10,000 psi Helium and in 10,000 psi Hydrogen 126