final report on rcs including preliminary action plan

DELIVERABLE 4.2

FINAL REPORT ON RCS INCLUDING PRELIMINARY ACTION PLAN

* Regulations, Codes, and Standards

FINAL

2013-12

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-2009-1 Grant Agreement Number 278796.

The project partners would like to thank the EU for establishing the Fuel cells and hydrogen framework and or supporting this activity.

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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.

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

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CONTENTS

1 INTRODUCTION ................................................................................................................. 4

2 CATEGORIZATION OF CONTAINMENT SOLUTIONS ................................................................ 5

3 EVOLUTION OF CONTAINERS CHARACTERISTICS RESULTING FROM THE

IMPLEMENTATION OF COMPOSITE MATERIALS .................................................................... 6

4 RCS LANDSCAPE ............................................................................................................. 7

4.1 Regulatory landscape .............................................................................. 7

4.2 Standards landscape ............................................................................... 8

5 ANALYSIS OF REGULATION AND STANDARDS ..................................................................... 9

5.1 Reference to standards ............................................................................ 9

5.2 ADR Definitions ........................................................................................ 9

5.3 Relevant standards ................................................................................ 10

5.4 ADR referenced standards for cylinders and tubes ............................... 11

5.5 Burst pressure ratio ................................................................................ 12

5.6 Periodic inspection ................................................................................. 12

5.7 Service life ............................................................................................. 13

6 BARRIERS AND GAPS TO BE ADDRESSED IN RCS FRAMEWORK – PRELIMINARY

RESULTS ........................................................................................................................ 15

APPENDIX 1:TRANSPORTABLE COMPOSITE HYDROGEN STORAGE - LIST OF

PUBLISHED DOCUMENTS ................................................................................................. 16

APPENDIX 2: TRANSPORTABLE COMPOSITE HYDROGEN STORAGE - LIST OF ACTIVE

WORK ............................................................................................................................ 30

APPENDIX 3 - REASONS PROVIDED BY BAM FOR THE NEED OF ATR D 3/10 AND ATD

D 4/10. .......................................................................................................................... 36

D 4..2 : Final report on RCS including preliminary action plan Report

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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.


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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.


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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 3 000 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,


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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 1968. 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 1985.

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.


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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.


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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 2.2.2.1.1 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 3 000 litres except that bundles intended for the transport of gases of Division 2.3 shall be limited to 1 000 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 3 000 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 6.2.2.5 mentions tubes in composite material:

6.2.5.5 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......


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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 12245:2009 2013 Cylinders, Types 2, 3, 4, Up to 3 000 l No limit specified

+ A1:2011 and 5 (no liner)

ISO 11120:1999 2013 Tubes, in steel (Type 1) Greater than 150 l up to 3 000 l

No limit specified

ISO 11119- 1: 2012 2013 Cylinders, Type 2 Up to 450 l No limit specified

ISO 11119- 2: 2012 2013 Cylinders, Type 3 Up to 450 l No limit specified

ISO/FDIS 11119- 3 2013 Cylinders, Type 4 Up to 450 l No limit specified

ISO/CD 17519 Not yet scheduled Tubes, [Types 3 and] 4 - Permanently mounted in a frame

From 450 l, up to [100 MPa]

10 000 l [addition of elements in brackets to scope is currently being proposed]

ISO 11515 Not yet scheduled

Tubes type 2, 3 and 4

Greater than 450 l, up to 3,000 l

106.7 MPa


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*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 6.2.2 Requirements for UN pressure receptacles which specify the applicable referenced standards for cylinders (6.2.2.1.1) on the one hand and tubes (6.2.2.1.2) 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 (6.2.2.1.1.). As a result tubes complying with ISO 11119-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 6.2.4., 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.


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5.5 Burst pressure ratio

The section describing the requirements applicable to pressure vessels is organised as follows:

6.2.2 Requirements for UN pressure receptacles

6.2.3 General requirements for non-UN pressure receptacle

6.2.4 Requirements for non-UN pressure receptacles designed, constructed and tested according to referenced standards

6.2.5 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 6.2.5.as specified in 6.2.5.5:

6.2.5.5 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:

- 1.67 for hoop wrapped pressure receptacles;

- 2.00 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 6.2.2.4 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.


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For non-UN composite pressure vessels:

ADR 6.2.4.2 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 6.2.2.1.1 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 6.2.2.5:

ISO 11119-1:2002 Gas cylinders of composite construction — Specification and test methods — Part 1: Hoop wrapped composite gas cylinders

ISO 11119-2:2002 Gas cylinders of composite construction — Specification and test methods — Part 2: Fully wrapped fibre reinforced composite gas cylinders with load-sharing metal liners

ISO 11119-3:2002 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


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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.


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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 3 000 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 11119-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 10 000 l covered by ISO 17519 (if we can justify by risk analysis for this value),

- Need to secure that ADR will refer to ISO 17519 for MEGC and trailers implementing tubes in composite material (Types 3 and 4) having a water capacity exceeding 450 l up to 10 000 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.


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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.


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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.


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European Agreement concerning the International Carriage of Dangerous Goods by Road (ADR) 2011

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 1968. 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 1985.

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-

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)

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.

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)

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 450


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EN 12245:2002 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 12257.

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.

EN 12245:2009 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 3 000 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 12257.

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 14427.

ISO/TR 13086-1:2011 Gas cylinders — Guidance for design of composite cylinders — Part 1: Stress rupture of fibres and burst ratios related to test pressure

Edition 1

This part of ISO/TR 13086 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 13086 are to support the development and revision of standards for fibre composite reinforced pressurized cylinders.


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ISO 11114-4:2005 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 11114-4:2005 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 3 000 l) for hydrogen and other embrittling gases.

ISO 11114-4:2005 only applies to seamless steel gas cylinders.

The requirements of ISO 11114-4:2005 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 11119-1:2002 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 11119-1 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 11119 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 11119 does not address the design, fitting and performance of removable protective sleeves. Where these are fitted they should be considered separately.


Edition 1

ISO 11119-2 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 11119 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 11119 does not address the design, fitting and performance of removable protective sleeves. Where these are fitted they should be considered separately.


21



Edition 1

ISO 11119-3 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 11119-3 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 11119-3 does not address the design, fitting and performance of removable protective sleeves.

ISO 11623:2002 Transportable gas cylinders -- Periodic inspection and testing of composite gas cylinders

Edition 1

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 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

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.

ASME BPVC-XII – 2010 BPVC Section XII-Rules for Construction and Continued Service of Transport Tanks

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.


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ASME STP-PT-003 Hydrogen Standardization Interim Report for Tanks, Piping, and Pipelines

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.

ASME STP-PT-004 Impregnated Graphite for Pressure Vessels

Impregnated graphite (also called impervious graphite) is a material that has been in industrial use for the past 60-70 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.

ASME STP-PT-005 Design Factor Guidelines for High-Pressure Composite Hydrogen Tanks

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.


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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.


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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 11114-4, 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.


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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 2007. 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 2007. 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 2008. 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


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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.

Publications Scope Rev. Copy

ASTM F326-96(2006) Standard Test Method for Electronic Measurement for Hydrogen Embrittlement From Cadmium-Electroplating Processes

1.1 This test method covers an electronic hydrogen detection instrument procedure for measurement of plating permeability to hydrogen. This method measures a variable related to hydrogen absorbed by steel during plating and to the hydrogen permeability of the plate during post plate baking. A specific application of this method is controlling cadmium-plating processes in which the plate porosity relative to hydrogen is critical, such as cadmium on high-strength steel.

This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use. For specific hazard statement, see Section 8.

1.2 The values stated in SI units are to be regarded as the standard. The values given in parentheses are for information only.

N


27

ASTM F519-10 Standard Test Method for Mechanical Hydrogen Embrittlement Evaluation of Plating/Coating Processes and Service Environments

1.1 This test method describes mechanical test methods and defines acceptance criteria for coating and plating processes that can cause hydrogen embrittlement in steels. Subsequent exposure to chemicals encountered in service environments, such as fluids, cleaning treatments or maintenance chemicals that come in contact with the plated/coated or bare surface of the steel, can also be evaluated.

1.2 This test method is not intended to measure the relative susceptibility of different steels. The relative susceptibility of different materials to hydrogen embrittlement may be determined in accordance with Test Method F1459 and Test Method F1624.

1.3 This test method specifies the use of air melted AISI E4340 steel per SAE AMS-S-5000 (formerly MIL-S-5000) heat treated to 260 – 280 ksi (pounds per square inch x 1000) as the baseline. This combination of alloy and heat treat level has been used for many years and a large database has been accumulated in the aerospace industry on its specific response to exposure to a wide variety of maintenance chemicals, or electroplated coatings, or both. Components with ultimate strengths higher than 260 – 280 ksi may not be represented by the baseline. In such cases, the cognizant engineering authority shall determine the need for manufacturing specimens from the specific material and heat treat condition of the component. Deviations from the baseline shall be reported as required by section 12.1.2. The sensitivity to hydrogen embrittlement shall be demonstrated for each lot of specimens as specified in section 9.5.

1.4 Test procedures and acceptance requirements are specified for seven specimens of different sizes, geometries, and loading configurations.

1.5 Pass/Fail Requirements—For plating/coating processes, specimens must meet or exceed 200 h using a sustained load test (SLT) at the levels shown in Table 3.

1.5.1 The loading conditions and pass/fail requirements for service environments are specified in Annex A5.

1.5.2 If approved by the cognizant engineering authority, a quantitative, accelerated (≤ 24 h) incremental step-load (ISL) test as defined in Annex A3 may be used as an alternative to SLT.

1.6 This test method is divided into two parts. The first part gives general information concerning requirements for hydrogen embrittlement testing. The second is composed of annexes that give specific requirements for the various loading and specimen configurations covered by this test method (see section 9.1 for a list of types) and the details for testing service environments.

1.7 The values stated in the foot-pound-second (fps) system in inch-pound units are to be regarded as standard. The values given in parentheses are mathematical conversions to SI units that are provided for information only and are not considered standard.

1.8 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.

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ASTM F1113-87(2005)e1 Standard Test Method for Electrochemical Measurement of Diffusible Hydrogen in Steels (Barnacle Electrode)

1.1 This test method covers the procedure for measuring diffusible hydrogen in steels by an electrochemical method.

1.2 This test method is limited to carbon or alloy steels, excluding austenitic stainless steels.

1.3 This test method is limited to flat specimens to which the cell can be attached (see 4.6 and 4.8).

1.4 This test method describes testing on bare or plated steel after the plate has been removed (see 4.4).

1.5 This test method is limited to measurements at room temperature, 20 to 25C (68 to 77F).


N

ASTM F1459-06 Standard Test Method for Determination of the Susceptibility of Metallic Materials to Hydrogen Gas Embrittlement (HGE)

1.1 This test method covers the quantitative determination of the susceptibility of metallic materials to hydrogen embrittlement, when exposed to high pressure gaseous hydrogen.

1.2 The values stated in SI units are to be regarded as the standard. The values given in parentheses are for information only.

This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.

N

ASTM F1624-09 Standard Test Method for Measurement of Hydrogen Embrittlement Threshold in Steel by the Incremental Step Loading Technique

1.1 This test method establishes a procedure to measure the susceptibility of steel to a time-delayed failure such as that caused by hydrogen. It does so by measuring the threshold for the onset of subcritical crack growth using standard fracture mechanics specimens, irregular-shaped specimens such as notched round bars, or actual product such as fasteners (2) (threaded or unthreaded) springs or components as identified in SAE J78, J81, and J1237.

1.2 This test method is used to evaluate quantitatively:

1.2.1 The relative susceptibility of steels of different composition or a steel with different heat treatments;

1.2.2 The effect of residual hydrogen in the steel as a result of processing, such as melting, thermal mechanical working, surface treatments, coatings, and electroplating;

1.2.3 The effect of hydrogen introduced into the steel caused by external environmental sources of hydrogen, such as fluids and cleaners maintenance chemicals, petrochemical products, and galvanic coupling in an aqueous environment.

1.3 The test is performed either in air, to measure the effect if residual hydrogen is in the steel because of the processing (IHE), or in a controlled environment, to measure the effect of hydrogen introduced into the steel as a result of the external sources of hydrogen (EHE) as detailed in ASTM STP 543.

1.4 The values stated in acceptable inch-pound units shall be regarded as the standard. The values stated in metric units may not be exact equivalents. Conversion of the inch-pound units by appropriate conversion factors is required to obtain exact equivalence.


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CGA PS-34:2009 CGA Position Statement on Applying Codes and Standards for Hydrogen Storage, Use and Dispensing Systems

(10/13/09)

This position statement provides details on the applicability of national codes and standards developed by a consensus process for compressed hydrogen gas and cryogenic liquid hydrogen storage systems. It recommends the use of consensus codes and standards for hydrogen storage instead of locally developed codes.

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APPENDIX 2: TRANSPORTABLE COMPOSITE HYDROGEN 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 receptacles, otherwise referred to interchangeably as tubes, vessels, or cylinders, of composite construction permanently mounted in a transport frame intended for the bulk transport of pressurized gases. These tubes are from 450 liters to 10 000 liters water capacity and working pressure up to 1000 bar. 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. This International Standard covers receptacles of filament-wound composite construction, using any design or method of manufacture suitable for the specified service conditions. Note: These composite receptacles are classified as “tubes” in many regulations and standards due their size (internal volume). The use of the term “cylinder” or “tube” in this International Standard is intended as a generic term that can be used in place of “receptacle”. Cylinders covered by this International Standard are designated as follows: Type III A Fully Wrapped Cylinder with a seamless metallic liner and composite reinforcement on both the cylindrical part and the dome ends Type IV - a Fully Wrapped Cylinder with a non-load sharing liner and composite reinforcement on both the cylindrical part and the dome ends

Not hydrogen specific

Transportable

Capacity: 450 l to 10

000 l

Type 3 and Type 4


31



ISO/FDIS 11515 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 3 000 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.


Transportable

Capacity: 450 l to 3000

l

Type 2, 3 and 4


32



ISO/FDIS 11119-1 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 11119 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 11119 does not address the design, fitting and performance of removable protective sleeves.

Where these are fitted they should be considered separately.

NOTE ISO 11439 applies to cylinders intended for use as fuel containers on natural gas vehicles and ISO 11623 covers periodic inspection and re-testing of composite cylinders.


Transportable

Max capacity: 150 l

Type 2 with seamless

liner


ISO/FDIS 11119-2 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 11119 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.


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 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.



NOTE ISO 11439 applies to cylinders intended for use as fuel containers on natural gas vehicles and ISO 11623 covers periodic inspection and re-testing of composite cylinders.


Transportable

Max capacity: 150 l

Type 3 with seamless

liner


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ISO/FDIS 11119-3 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 non-metallic liners

Edition 2

This part of ISO 11119 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


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. 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.



NOTE ISO 11439 applies to cylinders intended for use as fuel containers on natural gas vehicles and ISO 11623 covers periodic inspection and re-testing of composite cylinders


Transportable

Max capacity: 150 l

Type 4


34



ISO/NP 11119-4 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 11119 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 11119 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 11119 does not address the design, fitting and performance of removable protective sleeves. Where these are fitted they should be considered separately. NOTE ISO 11439 applies to cylinders intended for use as fuel containers on natural gas vehicles and ISO 11623 covers periodic inspection and re-testing of composite cylinders.


Transportable

Max capacity: 150 l

Type 3 with welded liners


ISO/TR 13086-2 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 11623 Transportable gas cylinders -- Periodic inspection and testing of composite gas cylinders

Edition 2

Revision of ISO 11623:2002


35


ISO/TC 58/SC 4

ISO/FDIS 19078 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 2

Revision of ISO 19078:2006.

ISO/TC 58 WG 7

ISO/NWIP 10783 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.


36

APPENDIX 3 - REASONS PROVIDED BY BAM FOR THE NEED OF ATR D 3/10

AND ATD D 4/10. “The ATR D 3/10 is necessary, because in the table in 6.2.4 RID/ADR no suitable standard is referenced for composite-tubes with a volume above 150 l up to 450 l. As only referenced standards are permitted to be applied, it was necessary to adopt a technical code according to 6.2.5 RID/ADR.

Although in the table in 6.2.4 EN 14245:2002 is referenced for cylinders up to 150 l volume, containing a note declaring that the standard may also be regarded as suitable for tubes up to 450 l volume, investigation of the consultancy bodies of BMVBS has shown, that the referenced version of EN 14245 is outdated, because in 2009 a revised and updated version had been published.

Therefore modifications and additions on technical requirements and provisions for testing had to be set up to reflect the improved level of state of the art technology.

Furthermore it had to be noted, that due to the development on the international level a new standard is under preparation (see prISO 11515) to set a new state of the art standard for composite tubes intended to replace EN 14245 once adopted and published. But adoption and publication of that new standard is not likely before 2 or 3 years from now.

As there is urgent need to issue approvals for composite-tubes up to 450 l volume, the ATR D 3/10 has been adopted to bridge the gap.

ATR D 3/10 may be applied within Germany from 01.08.2010. 6.2.5 of RID/ADR permit, that pressure receptacles constructed and approved according to a nationally recognized technical code may be used for transport throughout all RID Member States/ADR Contracting parties. Directive 1999/36/EC on transportable pressure equipment (applicable until 30 June 2011) and the new directive 2010/35/EU (applicable from 07 July 2011) permit pi-marking of such pressure receptacles.”

.......

“The use of technical codes recognized by the German competent authority in accordance with RID/ADR 6.2.5 is hereby confirmed for the use in the territory of the Federal Republic of Germany, only. A German ATR may be used in the territory of another RID/ADR-member state if it is accepted by the relevant national competent authority including the corrigendum by Nr. 155 VkBl. Heft 22-2010; S 554, rendering the fifth paragraph in above mentioned excerpt void.”

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final report on rcs including preliminary action plan

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