international forum on pressure vessels for hydrogen · pdf fileinternational forum on...
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Beijing
September 27-29, 2010
Joe Wong
International Forum on Pressure Vessels
for Hydrogen and Natural Gas Vehicles
COMPOSITE TANK TESTING,
CERTIFICATION, AND FIELD
PERFORMANCE
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POWERTECH – Hydrogen & CNG Services
Certification testing of individual high pressure components
Design Verification, Performance, End-of-Life testing of
complete fuel systems
Design, construction, and operation of Hydrogen Fill Stations
Safety Studies
Standards Development
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30% Hydrogen / 70% CNG Vehicles
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Hydrogen FCV Fleets (Ford) - Vancouver
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100% Hydrogen ICE Vehicles
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Hydrogen Highway to Whistler
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Composite Tank Designs
On–board vehicle fuel systems
• Every single hydrogen FCV OEM are using composite tanks
Industrial gas cylinders
Transportable bulk tanks
Stationary ground storage
1994 Ballard Fuel Cell Bus
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Why use Composite cylinders?
Light weight
Lower cost for higher pressures and larger cylinders
Less susceptible to fatigue cracks
High toughness and elongation of liner material
Low capital cost for manufacturing
Capable of large diameters
Ultra high pressure (1000bar)
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Large Volume Type 4 Storage
38 feet long
tanks (11.6M)
5300 lbs
(2,400 kg)
42 inches
diameter
Holds 10,000
SCM CNG
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COMPOSITE CYLINDERS FOR STATION GROUND
STORAGE
> Vehicle OEMs leading the advancement of 70 MPa onboard storage
> Up to 100 MPa storage tanks needed in the fueling stations to provide
fast filling of vehicles to 70 MPa
> Traditional steel designs cannot be used for this high pressure
> Data is needed to obtain regulatory approval of composite tanks
> ASME has recently approved the use of composite tanks for hydrogen
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Need for composite ground storage @100 MPa
> Steel ground storage tanks are difficult to manufacture
> Thick wall cylinders
> Small volume cylinders
> Hard to get materials
> Hydrogen embrittlement
> High capital cost
> Composite tank designs are scaled up from 35 MPa designs
> Only requires extra carbon fiber wraps
> Low capital costs
> Able to produce large volume tanks
> Liners are resistant to hydrogen embrittlement
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Vehicle Service Conditions
Road conditions very severe environment for vehicle pressure
vessels
> Temperature extremes (-40ºC to +85ºC in vehicles)
> Multiple fills from full to empty
> (pressure changes) = fatigue cracking
> Exposure to road environments and cargo spillage
> Vibration
> Vehicle fires
> Collision
> Exposure to fire sources
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Ground Storage Service Conditions
Conditions less severe than vehicle tanks
> Temperature extremes (-40ºC to +40ºC in stations)
> Tanks are always near full, very low pressure changes
> No exposure to road environments and cargo spillage
> No vibration except earthquake deformation
> No flammable materials in the vicinity
> Collision protection in stations
> Clearance distance around equipment
> Pressure activated relief devices
> Emergency shutdown systems
> Heavy support frames
> Regular scheduled maintenance & calibrations
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100 MPa Cylinder Development
Wall thickness
comparison - 35
MPa vs 70 MPa
cylinders
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APPLICABLE STANDARDS
Standard Hydrogen CNG
Transportable
storage
Vehicle
storage
Stationary
Storage
DOT FRP1 X X X
CAN/CSA B339 X X X
DOT CFFC X X X
ISO 11119-2 X X X
ISO 11119-3 X X X
CSA B51 Part 2 X X X
ANSI NGV2 X X
ANSI HGV2 X X
ISO 15869 X X
ISO 11439 X X
SAE J2579 X X
CSA B51 Part 3 X X X
ISO TC197 WG15 X X
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FAILURE INCIDENTS REPORTED BY FAILURE CAUSE
Data classified according to unique failure causes:
Mechanical Damage – External
abrasion and/or impact
Environmental Damage – External
environment assisted, typically SCC
Overpressure – Faulty fueling
equipment or faulty CNG cylinder
valves
Vehicle fire – Faulty PRDs or lack of
PRDs; localized fires
Plastic Liner Issues – Man. defects
incl. cracking at end boss/liner
interface, flawed welds, liner seal
failures
Metal Liner Issues – Man. defects
incl. pinhole leaks, laminations, poor
heat treat practice
5
12
3
16
6
8
1
3
0
2
4
6
8
10
12
14
16
18
Mechanical
Damage
Environmental
Damage
Overpressure Vehicle Fire Plastic Liner
Issues
Metal Liner
Man. Issues
User Error Unknown
Cause
Failure Cause
No
. o
f F
ailu
re In
cid
en
ts
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Standard Tests for Design Qualification
Performance tests were designed and validated including:
Ambient Cycling Test
Environmental Test
Extreme Temperature Pressure Test
Hydrostatic Burst Test
Composite Flaw Test
Drop Test
Accelerated Stress Rupture Test
Permeation Test
Hydrogen Cycling Test
Bonfire test
Gunfire Penetration Test
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Test Methods
Performance based standards require testing conditions that closely simulate service conditions
Need to ensure accuracy measurement and control of:
tank temperature
tank pressure
test medium
rate of testing
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Tank Testing - Burst Test
Burst testing up to 2,800 bar
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BURST PRESSURE VERSUS WORKING PRESSURE
As pressure increases, Safety Margin between WP and BP increases dramatically. CNG service shows Safety Margin at 200 bar WP adequate.
0
200
350
700
0
450
1,550
0
350
700
1050
1400
1750
0 140 280 420 560 700
Service pressure (bar)
Bu
rst
pre
ss
ure
(b
ar)
Burst Pressure (2.25 x SP)
Service Pressure (SP)
850 bar
790
440 bar
250 bar
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Tank Testing - Hydraulic Pressure
Environmental and
chemical effects
Flaw/Damage Tolerance
Drop Test
Powertech Cylinder Test Facilities
Hydraulic pressure cycling up to
1,500 bar
Extreme temperature cycle test
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Pressure Cycle Testing – Vehicles
> Minimum pressure - 10% service pressure –
> Maximum pressure - 125% service pressure
> Failure mode must be leak, not rupture
> Minimum # of cycles 11,250 cycles (ANSI/CSA NGV2)
> 2 fills per day x 15 years = 10,950 fills
> 10,950 fills = 5.5 million kilometers
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Pressure Cycle Testing – Ground Storage
> Study by Powertech on pressure fluctuation in CNG fueling
stations
> Monitored pressure in cascade storage banks in 3 fueling
stations
> Station fueled approximately 100 vehicles per day
> Findings for cycle pressure range:
> Worst case 50% -100% approx 5000 cycle per year
> Typical 70 % - 125% approx.10000 cycle per year
> Worst case for vehicles 10% -125% of service pressure
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Pressure Cycle Testing – Ground Storage
R ratio = min pressure /max pressure
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0 50000 100000 150000 200000 250000 300000 350000 400000
# pressure cycles to failure
R r
ati
o
Type 3 Cylinder
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Damage Tolerance – Gunfire Test
Type 3 composite tank
First bullet made 75 mm
cut in carbon fiber
and exposed
aluminum liner
Second bullet caused the
release of the tank’s
hydrogen gas
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Plastic Liner Issues
The long term integrity of the connection between the plastic liner and the metal end boss Different designs: mechanical connection, O ring seal, adhesive seal
Different liner materials
Aging effects on the plastic liner due to extreme temperatures
Welding of plastic liners
Permeations issues
Liner buckling
Static Discharge
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Recent Work to Support Standards
Development
Hydrogen test validation for SAE J2579 - NREL
Localized fire testing - NHTSA
Crash Integrity of Tanks - Battelle
Fueling protocol testing for SAE J2601 - SAE
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SAE J2579 Program Overview
Tests to validate SAE J2579 composed of three parts:
I. Verify that the vehicle storage validation tests specified in J2579
can be performed by a test facility
II. Verify that vehicle storage systems that have failed in past vehicle
service would not pass the J2579 tests
III. Verify that vehicle storage systems that have not failed in past
vehicle service will either: 1) pass the J2579 tests or, 2) fail the
J2579 tests only when the reasons for failure are understood and
would be expected to occur in vehicle service.
Contract by the National Renewable Energy Laboratory (NREL), working
with the Society of Automotive Engineers International (SAE).
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Validation of Test Sequence
Safety Concerns
Powertech SAE J2579 Test Setup Safety Considerations
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Ignition of 25% Hydrogen Mixture
(approaching stoichiometric)
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Localized Fire Testing –
Purpose of NHTSA Program
• Since year 2000, leading cause of CNG cylinder failures is vehicle fire, and single leading cause of vehicle fire failures is localized fire effects
• Objective is to verify effectiveness of a localized flame test developed previously in a Transport Canada study
• Objective to be achieved by the “…evaluation of various fire protection technologies that will reduce the risk of cylinder failure during a vehicle fire”
• The localized fire test developed for Transport Canada involved meeting several precise time and temperature criteria occurring on a tank surface as defined by an OEM, and was found not to be adaptable to evaluating the performance of various fire protection technologies
• A more versatile flame impingement test was developed based on vehicle fire data
• Maximum temperature exceeding 900ºC
• Duration of 30 minutes (duration of tire fire)
• Fire length that is 25% of the length covered by a standard 1.65m fire
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Localized Fire Test Programs – Conclusions
• There are protective coating and wrap systems that work
• Protective systems are available that are:
• Cost-effective, minimal added weight, minimal added wall thickness
• There are remote fire detection systems that work
Intumescent epoxy after 30 min @ 1000 deg C Thermal wrap undergoing localized fire
test
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Hydraulic Crush Test (150,000 kgf)
Used hydraulic ram to attempt crush of pressurized hydrogen tank
Test ended at 150,000 kgf when reinforced concrete wall on opposite side of ram broke
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2 Ton Impact on Tank
Battelle Program funded by NHTSA
Type 3 and Type 4 tanks
vertical and horizontal impacts
350 and 700 bar tanks
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Multi-Client 70 MPa Hydrogen Fast Fill Study
Outputs of the study to support J2601:
Minimum fueling time at each ambient condition to safely fill all fuel
systems
Pre-cooling levels for each ambient condition
Energy required for pre-cooling
Temperature gradients throughout the fuel system
Durability of fuel system under extreme fueling conditions
Performance data of station components (flowmeter, flow controller,
nozzles, hoses, compressors, etc.)
Consortium members: Air Liquide, BP, Nippon Oil, Sandia (US DOE),
Shell, Iwatani, Chrysler, Ford, GM, Nissan, Honda, Toyota.
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CONTACT
Joe Wong, P.Eng.
Manager, Clean Transportation Engineering
Powertech labs Inc,
12388 88th Avenue,
Surrey, BC, Canada, V3W 7R7
Tel: 1-604-590-7426
Email: [email protected]
Website: www.powertechlabs.com