nd SECOND EUROPEAN SUMMER 2 nd SECOND EUROPEAN SUMMER 2 SCHOOL - - PowerPoint PPT Presentation

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nd SECOND EUROPEAN SUMMER 2 nd SECOND EUROPEAN SUMMER 2 SCHOOL HYDROGEN SAFETY SCHOOL HYDROGEN SAFETY BELFAST BELFAST JULY 30 TH TH - - AUGUST 8 AUGUST 8 TH TH , 2006 , 2006 JULY 30 SAFETY OF HYDROGEN CYLINDERS AND PRESSURE VESSELS

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2 2nd

nd SECOND EUROPEAN SUMMER

SECOND EUROPEAN SUMMER SCHOOL HYDROGEN SAFETY SCHOOL HYDROGEN SAFETY BELFAST BELFAST JULY 30 JULY 30TH

TH-

  • AUGUST 8

AUGUST 8TH

TH, 2006

, 2006

Hervé Barthélémy

SAFETY OF HYDROGEN CYLINDERS AND PRESSURE VESSELS

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2 World leader in industrial and medical gases

  • 1. INTRODUCTION AND DIFFERENT TYPES

OF PRESSURE VESSELS

  • 2. SOME HISTORY
  • 3. DESIGN AND MANUFACTURING

SAFETY OF HYDROGEN CYLINDERS AND PRESSURE VESSELS

  • 4. SUITABLE MATERIALS FOR PRESSURE

VESSELS

  • 6. TESTS APPROVAL & REGULATION
  • 7. NEW TRENDS DUE TO HYDROGEN ENERGY
  • 8. CONCLUSION
  • 5. POTENTIAL SOURCES OF INCIDENTS

INVOLVING GAS CYLINDERS

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3 World leader in industrial and medical gases

  • 1. INTRODUCTION AND DIFFERENT

TYPES OF PRESSURE VESSELS

Type I : pressure vessel made of metal Type II : pressure vessel made of a thick metallic liner hoop wrapped with a fiber resin composite Type III : pressure vessel made of a metallic liner fully-wrapped with a fiber-resin composite Type IV : pressure vessel made of polymeric liner fully-wrapped with a fiber-resin composite

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4 World leader in industrial and medical gases

4 pressure vessels types

  • 1. INTRODUCTION AND DIFFERENT

TYPES OF PRESSURE VESSELS

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5 World leader in industrial and medical gases

Different types of pressure vessels

Type I cylinder Type II vessel Type III or IV vessel Toroid composite vessel

  • 1. INTRODUCTION AND DIFFERENT

TYPES OF PRESSURE VESSELS

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6 World leader in industrial and medical gases

  • 2. SOME HISTORY

Welded cylinder : test pressure : 60 bar

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7 World leader in industrial and medical gases

Gas transport - 1857

  • 2. SOME HISTORY
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8 World leader in industrial and medical gases

  • 2. SOME HISTORY
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9 World leader in industrial and medical gases

The experimentation of composite

vessels started in the 50s

Composite vessels were introduced

for space and military applications

  • 2. SOME HISTORY
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10 World leader in industrial and medical gases

  • 3. DESIGN AND MANUFACTURING

Metallic vessels and composite

vessels are very different :

  • The metal is isotropic, the composite is

anisotropic

  • The failure modes are different
  • The ageing is different
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11 World leader in industrial and medical gases

  • 3. DESIGN AND MANUFACTURING

Main strains considered for the metallic pressure vessels design (type I and metallic liner)

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12 World leader in industrial and medical gases

  • 3. DESIGN AND MANUFACTURING

Multi-layered element and vessel meshes example

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13 World leader in industrial and medical gases

  • 3. DESIGN AND MANUFACTURING

Type I :

  • From plates
  • From billets
  • From tubes

3 different manufacturing processes

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14 World leader in industrial and medical gases

Different production methods

  • 3. DESIGN AND MANUFACTURING
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  • 3. DESIGN AND MANUFACTURING

Principle of metallic tank manufacturing processes (1 : from plates / 2 : from billets / 3 : from tubes

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  • 3. DESIGN AND MANUFACTURING

Production process from steel plate

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  • 3. DESIGN AND MANUFACTURING

Production process from steel plate

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  • 3. DESIGN AND MANUFACTURING

Manufacturing from plate

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  • 3. DESIGN AND MANUFACTURING

Stock of steel bars for cylinders made from billets

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20 World leader in industrial and medical gases

  • 3. DESIGN AND MANUFACTURING

Cylinders made from billets Different forging steps

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  • 3. DESIGN AND MANUFACTURING

Steel cylinders spinning process

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22 World leader in industrial and medical gases

  • 3. DESIGN AND MANUFACTURING

Stock of aluminium billets

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23 World leader in industrial and medical gases

  • 3. DESIGN AND MANUFACTURING

Aluminium cylinders made from cold extrusion

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24 World leader in industrial and medical gases

  • 3. DESIGN AND MANUFACTURING

Aluminium cylinders made from hot extrusion

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25 World leader in industrial and medical gases

  • 3. DESIGN AND MANUFACTURING
  • From the polymer or the monomers by the

rotomolding process

  • From tubes : polymeric tubes (made by

extrusion blow moding)

Polymers liners :

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26 World leader in industrial and medical gases

  • 3. DESIGN AND MANUFACTURING

Winding machine and the 3 winding possibilities

CNRS-LMARC-Besançon-France

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27 World leader in industrial and medical gases

  • 3. DESIGN AND MANUFACTURING

Composite cylinders

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28 World leader in industrial and medical gases

  • 3. DESIGN AND MANUFACTURING

Composite cylinders being wrapped with amaride fiber

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29 World leader in industrial and medical gases

  • 4. SUITABLE MATERIALS FOR

HYDROGEN HIGH PRESSURE VESSELS

Risk of hydrogen embrittlement :

  • Environment
  • Material
  • Design and surface conditions
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30 World leader in industrial and medical gases

Steels acceptable for hydrogen pressure storage (ISO 11114-1)

Type of steel Note

Normalized and carbon steels Stainless steels Quenched and tempered steels Embrittlement to be assessed if (C + Mn/6) high Some of them can be sensitive to embrittlement (ex. : 304) More used (ex. : 34CrMo4) ; Embrittlement to be assessed if Rm > 950 Mpa.

  • 4. SUITABLE STEELS
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31 World leader in industrial and medical gases

Specimens for compact tension test

  • 4. TEST METHODS
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Tensile specimen for hydrogen tests (hollow tensile specimen) (can also be performed with specimens cathodically charged or with tensile spencimens in a high pressure cell)

  • 4. TEST METHODS
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Cell for delayed rupture test with Pseudo Elliptic Specimen

Pseudo Elliptic Specimen

  • 4. TEST METHODS
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Tubular specimen for hydrogen assisted fatigue tests

Inner notches with elongation measurement strip

  • 4. TEST METHODS
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35 World leader in industrial and medical gases

Disk testing method – Rupture cell for embedded disk-specimen

1. Upper flange 2. Bolt Hole 3. High-strength steel ring 4. Disk 5. O-ring seal 6. Lower flange 7. Gas inlet

  • 4. TEST METHODS
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Example of a disk rupture test curve

  • 4. TEST METHODS
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37 World leader in industrial and medical gases

1) The influence of the different parameters shall be addressed. 2) To safely use materials in presence of hydrogen, an internal specification shall cover the following :

  • The « scope », i.e. the hydrogen pressure,

the temperature and the hydrogen purity

  • The material, i.e. the mechanical properties,

chemical composition and heat treatment

  • The stress level of the equipment
  • The surface defects and quality of finishing
  • And the welding procedure, if any
  • 4. H2 EMBRITTLEMENT - RECOMMENDATION
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38 World leader in industrial and medical gases

Permeation rate through the polymeric

liner :

  • Permeation is specific of type IV vessels. It

is the result of the H2 gas dissolution and diffusion in the polymer matrix

  • H2 is a small molecule, and thus the

permeation is enhanced. This leads to the development of special polymers

  • Polyethylene and polyamide are the most

used liners for type IV tanks

  • 4. COMPOSITE CYLINDERS –

SUITABLE MATERIALS

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39 World leader in industrial and medical gases

No specific issue with aluminium

alloys (except if presence of mercury or water)

  • 4. COMPOSITE CYLINDERS –

SUITABLE MATERIALS

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40 World leader in industrial and medical gases

Range of fiber mechanical properties

Fiber category Glass Amarid Carbon ~ 70 - 90 Tensile modulus (GPa) Tensile strength (MPa) Elongation (%) ~ 40 - 200 ~ 230 - 600 ~ 3300 - 4800 ~ 3500 ~ 3500 - 6500 ~ 5 ~ 1 - 9 ~ 0,7 – 2,2

  • 4. COMPOSITE CYLINDERS –

SUITABLE MATERIALS

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41 World leader in industrial and medical gases

  • 4. MATERIALS SUITABLE FOR

HYDROGEN HIGH PRESSURE VESSELS

Hydrogen requires special attention for the choice of : For type IV, permeation measurement is required (specified rate < 1 cm3/l/h). Material test generally requested to check “H2 embrittlement”

  • the polymer (type IV tanks)
  • the steel (types I, II and III tanks)
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42 World leader in industrial and medical gases

5.1. Type I cylinders 5.2. Composite cylinders

  • 5. POTENTIAL SOURCES OF

INCIDENTS

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43 World leader in industrial and medical gases

Defect of the billet (continuous casting) From the original materials

5.1. TYPE I CYLINDERS

MANUFACTURING DEFECTS

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44 World leader in industrial and medical gases

During forging Billet : eccentricity – excessively thin cylinder base Cross section showing thickness remaining at bottom

5.1. TYPE I CYLINDERS

MANUFACTURING DEFECTS

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45 World leader in industrial and medical gases

Tube : leak at cylinder base

5.1. TYPE I CYLINDERS

MANUFACTURING DEFECTS During forging

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46 World leader in industrial and medical gases

Plate : crack resulting from extremely severe deformation

5.1. TYPE I CYLINDERS

MANUFACTURING DEFECTS During forging

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  • Pre-existing defects

Shoulder shaping

  • Improper preheating

5.1. TYPE I CYLINDERS

MANUFACTURING DEFECTS

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48 World leader in industrial and medical gases

Neck crack

Neck and shoulder cracks due to sustained load cracking

5.1. TYPE I CYLINDERS

MANUFACTURING DEFECTS

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49 World leader in industrial and medical gases

Aluminium cylinders with coarse grain structure in the neck / shoulder region

5.1. TYPE I CYLINDERS

MANUFACTURING DEFECTS

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50 World leader in industrial and medical gases

  • Steel : improper treatment may lead to

brittleness at low temperature Heat treatment

  • Aluminium alloys : some materials may become

sensitive to intercrystalline or stress corrosion

5.1. TYPE I CYLINDERS

MANUFACTURING DEFECTS

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51 World leader in industrial and medical gases

Marking - Stampmarking Surface defects

5.1. TYPE I CYLINDERS

MANUFACTURING DEFECTS

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52 World leader in industrial and medical gases

  • Relevant for HP liquefied gases –

Use of bursting disc Overfilling

  • Excessive pressure (or stress)
  • CO / CO2 / H2O stress corrosion cracking

IN SERVICE DEFECTS

5.1. TYPE I CYLINDERS

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Gas material compatibility H2 embrittlement Other gases : see ISO 11114 IN SERVICE DEFECTS

5.1. TYPE I CYLINDERS

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  • External : severe environment (seaside…)

Corrosion

  • Internal :
  • O2, CO2 with water ingress

Steel cylinders – Internal corrosion IN SERVICE DEFECTS

5.1. TYPE I CYLINDERS

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Corrosion

  • Internal :
  • CO / CO2 / H2O stress corrosion cracking

Steel cylinders – Stress corrosion IN SERVICE DEFECTS

5.1. TYPE I CYLINDERS

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56 World leader in industrial and medical gases

Corrosion

  • Internal :
  • Corrosion of AA 6061 with tap water.

Reduction of fatigue life for composite cylinders External impact IN SERVICE DEFECTS

5.1. TYPE I CYLINDERS

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57 World leader in industrial and medical gases

  • Local : (local reduction of mechanical proper-

ties, thinning of the wall, local swelling) Fires Swelling and leak following applications of torch IN SERVICE DEFECTS

5.1. TYPE I CYLINDERS

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58 World leader in industrial and medical gases

Fires

  • Arc burns

Swelling and leak following applications of torch IN SERVICE DEFECTS

5.1. TYPE I CYLINDERS

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59 World leader in industrial and medical gases

Foreign bodies (internal) Risk of violent reactions with O2 and other

  • xidising gases

IN SERVICE DEFECTS

5.1. TYPE I CYLINDERS

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60 World leader in industrial and medical gases

FAILURE OF A HYDROGEN TRANSPORT VESSEL IN 1980

5.1. H2 REPORTED ACCIDENTS

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61 World leader in industrial and medical gases

FAILURE OF A HYDROGEN TRANSPORT VESSEL IN 1983. HYDROGEN CRACK INITIATED ON INTERNAL CORROSION PITS

5.1. H2 REPORTED ACCIDENTS

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62 World leader in industrial and medical gases

HYDROGEN CYLINDER BURSTS INTERGRANULAR CRACK

5.1. H2 REPORTED ACCIDENTS

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63 World leader in industrial and medical gases

VIOLENT RUPTURE OF A HYDROGEN STORAGE VESSEL

5.1. H2 REPORTED ACCIDENTS

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64 World leader in industrial and medical gases

H2 VESSEL. HYDROGEN CRACK ON STAINLESS STEEL PIPING

5.1. H2 REPORTED ACCIDENTS

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65 World leader in industrial and medical gases

No real experience of accidents because this is new types of cylinders, but :

5.2. COMPOSITE CYLINDERS

  • For metallic liner, see 5.1
  • For fiber and matrix risk of :
  • Delamination
  • Resistance to fire
  • Resistance to impact
  • « Blistering » for plastic liner
  • Leak and/or permeation for plastic liner
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  • 6. TESTS APPROVAL & REGULATION

Cylinders used to transport gases :

  • The Transportable Pressure Equipment

Directive (TPED) which relies on the ADR/RID and the standards

  • At international level, a similar regulation

is being prepared by the United Nations (ISO standards)

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67 World leader in industrial and medical gases

Hydrogen stations :

  • The Pressure Equipment Directive (PED)

in Europe

  • ASME code in North America

Hydrogen tanks used on vehicles

(no yet any regulation in place, the exemption often based on ISO TC 197 (ISO DIS 15869)

  • 6. TESTS APPROVAL & REGULATION
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68 World leader in industrial and medical gases

STRUCTURE CEN/TC 23 – Gas cylinders

  • Dr. C. Jubb

SC2

Fittings

  • Dr. H. Barthélémy

SC3

Operational requirements

  • Mr. K. Markhoff

SC1

Cylinders design

  • Dr. R. Irani
  • 6. TESTS APPROVAL & REGULATION
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69 World leader in industrial and medical gases

SC1 Cylinder design

WG1

Seamless steel cylinders

  • Mr. Ongaro

WG2

Welded/brazed cylinders excluding cylinders for LPG

  • Mr. M. Riehl-Gerling

WG4

Composite cylinders

  • Mr. E. Nicholson

WG3

Aluminium cylinders

  • Dr. H. Barthélémy

WG5

Non refillable cylinders

  • Dr. H. Barthélémy
  • 6. TESTS APPROVAL & REGULATION
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70 World leader in industrial and medical gases

SC3 Operational requirements

WG1

Filling conditions

  • Dr. Karl

WG2

Inspection and periodic testing

  • Dr. R. Irani

WG3

Identification of cylinders and contents

  • Dr. H. Barthélémy

WG5

Manifold receptacles

  • Mr. P. Thomas
  • 6. TESTS APPROVAL & REGULATION
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71 World leader in industrial and medical gases

STRUCTURE ISO/TC 58 – Gas cylinders

  • Dr. C. Jubb

SC3

Cylinder design

  • Dr. W. Hepples

SC4

Operational requirements

  • Mr. R. Smith

WG7

Compatibility between gases and materials

  • Dr. H. Barthélémy

SC2

Cylinders fittings

  • Dr. H. Barthélémy

WG10

Fitting of valves to gas cylinders

  • Dr. H. Barthélémy
  • 6. TESTS APPROVAL & REGULATION
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72 World leader in industrial and medical gases

SC2 Cylinder fitting

WG4

Valve stem and cylinder neck thread

  • Dr. H. Barthélémy

WG5

Yoke type outlets for breathing air for diving

  • Mr. S. Aris

WG7

Determination of toxicity of gas mixtures

  • Dr. H. Barthélémy

WG6

Gas cylinder valves Specification and testing

  • Mr. S. Aris

WG9

Valve connections for gases of high purity

  • Dr. H. Barthélémy

WG11

Allocation of valve

  • utlets
  • Dr. H. Barthélémy

WG12

Specifications and tests for LPG valves

  • Mr. P. O’Connell
  • 6. TESTS APPROVAL & REGULATION
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SC3 Cylinder design

WG18

Welded aluminium alloy cylinders

  • Dr. H. Barthélémy

WG17

Compressed natural gas cylinders for road vehicles

  • Mr. C. Webster

WG19

Test methods on fracture performance for high strength aluminium

  • Mr. L. Birch

WG21

Refillable welded steel gas cylinders

  • Mr. S. Gentry

WG23

Welded steel pressure drums

  • Mr. A. Fouet

WG24

Factory of safety for composite cylinders

  • Mr. N. Newhouse
  • 6. TESTS APPROVAL & REGULATION
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74 World leader in industrial and medical gases

SC3 Cylinder design

WG26

Seamless steel cylinders

  • Mr. G. König

WG27

Composite cylinders

  • Mr. M. Trudgeon

WG28

Seamless steel tubes

  • Mr. S. Bertino

WG25

Welded stainless steel cylinders

  • Mr. K. Beck

WG29

Revision of ISO 11118:1999

  • Mr. S. Gentry

WG30

Revision of ISO/TR 13763:1994

  • Mr. L. Birch
  • 6. TESTS APPROVAL & REGULATION
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75 World leader in industrial and medical gases

SC4 Operational requirements

WG1 Rejection criteria for Materials gas cylinders

  • Dr. R. Irani

WG2 Acoustic emission

  • Dr. H. Barthélémy

WG6 Cylinder identification

  • Dr. H. Barthélémy

WG7 Valve removal

  • Dr. W. Dörner

WG8 Bundles

  • Mr. K. Markhoff
  • 6. TESTS APPROVAL & REGULATION
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SEAMLESS STEEL LIST OF DESIGN STANDARDS

  • 6. TESTS APPROVAL & REGULATION

EN ISO 9809 : 1999 Part 2 : with tensile strength > or equal to 1 100 MPa Part 3 : Normalized steel cylinders Part 4 : with a Rm value of < 1 100 MPa Seamless steel Part 1 : with tensile strength < 1 100 MPa

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77 World leader in industrial and medical gases

SEAMLESS ALUMINIUM

EN ISO 7866 : 1999 Seamless aluminium Design, construction and testing

WELDED STEEL

ISO 4706 : 1989 Welded steel Part 1 : Test pressure 60 bar and below Part 2 : Test pressure > 60 bar

LIST OF DESIGN STANDARDS

  • 6. TESTS APPROVAL & REGULATION
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78 World leader in industrial and medical gases

WELDED STAINLESS STEEL

ISO FDIS 18172 Welded stainless steel Part 1 : Test pressure 6 MPa and below

WELDED ALUMINIUM

ISO 20703 : 2006 Welded aluminium Design, construction and testing Part 2 : Test pressure > 6 MPa

LIST OF DESIGN STANDARDS

  • 6. TESTS APPROVAL & REGULATION
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79 World leader in industrial and medical gases

COMPOSITE

ISO 11119 : 2002 Composite Part 1 : Hoop wrapped Part 2 : Fully wrapped fibre reinforced composite gas Cylinders with load-sharing metal liners Part 3 : Fully wrapped fibre reinforced composite gas cylinders with non load-sharing metallic or non-metallic liners

LIST OF DESIGN STANDARDS

  • 6. TESTS APPROVAL & REGULATION
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NON-REFILLABLE

ISO 11118 : 1999 Non-refillable Specification and test methods

LIST OF DESIGN STANDARDS

  • 6. TESTS APPROVAL & REGULATION
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81 World leader in industrial and medical gases

TUBES

ISO 11120 : 1999 Refillable seamless steel Design construction and testing

LIST OF DESIGN STANDARDS

  • 6. TESTS APPROVAL & REGULATION
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LIST OF DESIGN STANDARDS

  • 6. TESTS APPROVAL & REGULATION

DRUMS

ISO/CD 21172 Part 1 : Capacities up to 1 000 liters Part 2 : Capacities up to 3 000 liters

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83 World leader in industrial and medical gases

VEHICLE TANKS

ISO 11439 : 2000 High pressure cylinders for the on- board storage of natural gas as a fuel for automative vehicles

LIST OF DESIGN STANDARDS

  • 6. TESTS APPROVAL & REGULATION

ISO/DIS 15869 Hydrogen vehicle tanks

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  • 7. NEW TRENDS DUE TO HYDROGEN

ENERGY

Consumption (Nm3/h) Type of supply

< 100 Nm3/h From 1 to several hundreds Nm3/h A few thousands Nm3/h 200 or 300 bar cylinders 200 or 300 bar trailers - 20 K Liquid tank – small on site production (electrolyser/ reforming etc…) Pipelines – on-site production

Industrial hydrogen conventional delivery in 2006

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Compared to industrial gas, hydrogen

energy has brought new constraints :

  • Fuel for transportation : weight and

volume savings

  • Stationary applications (back-up power

supply or power generator for residential) : cost

  • Portable applications (computers, mobile

phone, etc…) : weight and volume savings

  • 7. NEW TRENDS DUE TO HYDROGEN

ENERGY

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Cm and Cv as a function of the pressure (types III and IV)

Cm : weight performance : mass of H2 stored divided by the mass of the vessel (% wt) Cv : volume performance : mass of H2 stored divided by the external volume of the vessel (g/l)

  • 7. NEW TRENDS DUE TO HYDROGEN

ENERGY

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87 World leader in industrial and medical gases

Stationary fuel cell power supply equipped with conventional 200 bar type I vessels (Axane technology)

  • 7. NEW TRENDS DUE TO HYDROGEN

ENERGY

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Fast filling station with type II buffers

  • 7. NEW TRENDS DUE TO HYDROGEN

ENERGY

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DoE requirements for transportation

System gravimetric density (kWh/kg) (% wt) System volumetric density (kWh/kg) kgH2/100 l) 2005 2010 2015 1,5 4,5 1,2 3,6 2 6 1,5 4,5 3 9 2,7 8,1

  • 7. NEW TRENDS DUE TO HYDROGEN

ENERGY

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  • 8. CONCLUSION

Main features for H2 pressure vessel types in 2006

Type I Type II Type III Type IV Technology mature Cost performance Weight performance ++ Pressure limited to 300 bar (⇒ ⇒ ⇒ ⇒ density : –) + Pressure not limited (⇒ ⇒ ⇒ ⇒ density : +) For P < 350 bar; (700 bar under development ) For P < 350 bar; (700 bar under development ) ++ + – – + + –