ASME STP-PT-003-2005 HYDROGEN STANDARDIZATION INTERIM REPORT For Tanks Piping and Pipelines.pdf

1、Designator: Meta Bold 24/26Revision Note: Meta Black 14/16STP/PT-003HYDROGENSTANDARDIZATIONINTERIM REPORTForTanks, Piping, and PipelinesSTP/PT-003 HYDROGEN STANDARDIZATION INTERIM REPORT for Tanks, Piping, and Pipelines Date of Issuance: June 6, 2005 This report was prepared as an account of work sp

2、onsored by the National Renewable Energy Laboratory (NREL) and the American Society of Mechanical Engineers (ASME). Neither ASME, ASME Standards Technology, LLC (ASME ST-LLC), JBDIMMICK LLC, Air Products and Chemicals Inc., nor others involved in the preparation or review of this report, nor any of

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9、rmission of the publisher. ASME Standards Technology, LLC Three Park Avenue, New York, NY 10016-5990 ISBN No. 0-7918-2992-8 Copyright 2005 by ASME Standards Technology, LLC All Rights Reserved H2Standardization Interim Report STP/PT-003 TABLE OF CONTENTS FOREWORD x ABSTRACT .xii PART I - Review of E

10、xisting Reference Standards to Support New Code Rules for High-Pressure Hydrogen Vessels 1 1 INTRODUCTION . 2 1.1 General Background of Code Work for 15,000 psi Hydrogen Vessels. 2 1.2 Reference Standards 3 1.3 Steel Cylinder Designs 3 1.4 Composite Cylinder Designs. 4 1.5 Stationary Storage Vessels

11、 4 1.6 Performance Based vs. Prescriptive Standards . 5 1.7 Reference Performance Based Standards 5 1.8 Potential for a New Performance Code . 6 1.9 Performance Standards Dependent on Design Calculations . 6 1.10 Potential Design Code for Hoop-Wrapped Vessels. 6 1.11 Potential for a Full-Composite C

12、ylinder Design Code 7 2 COMPARISON OF OPERATING MARGINS FOR EXISTING STANDARDS . 9 2.1 Operating Margin Definition. 9 2.2 Maximum Normal Operating Pressure (MNOP) 9 2.3 ASME Design Pressure and MNOP 9 2.4 MNOP for Non-Code Reference Standards 10 2.5 MNOP by Vessel Usage 10 2.5.1 ASME Storage Vessel

13、MNOP . 10 2.5.2 DOT Compressed Gas Cylinder MNOP 10 2.5.3 MNOP for ISO Gas Cylinders 11 2.5.4 MNOP for Vehicle Fuel Containers. 11 2.6 Normal Operating Pressure (NOP) 12 2.7 Maximum Pressure During Upsets or Fire Exposure 12 2.8 Burst Pressure 13 2.8.1 Burst Pressure of Composite Cylinders and Vesse

14、ls 13 2.8.2 Burst Pressure of Metal Cylinders and Vessels 14 2.8.3 Burst Pressure for DOT Metal Gas Cylinders 16 2.9 Burst Pressure of ISO Metal Gas Cylinders 17 2.10 Summary of Margin Definitions 17 2.11 Composite Stress Ratio Margins for Composites 17 2.11.1 DOT-3AA Specification Margin 17 2.11.2

15、DOT-3AA Margins Further Reduced. 18 2.12 Findings from Comparison of Margins between Different Standards. 18 2.13 Conclusions from Comparison of Margins 20 2.13.1 DOT FRP-1 Anomaly 20 2.13.2 Selection of Calculated over Design Margins for Metal Designs 20 iii STP/PT-003 H2Standardization Interim Rep

16、ort 2.13.3 Primary Factors Affecting Margins 21 2.14 Summary of Comparative Margins 23 2.14.1 ASME Code Vessels.23 2.14.2 Gas Cylinders for Transportation23 2.14.3 Gas Cylinders for Vehicle Fuel Tanks23 3 MANUFACTURING AND IN-SERVICE INSPECTION AND TEST PRACTICES IMPACTING MARGINS 24 3.1 Review of E

17、xisting Inspection.24 3.2 Review of Existing Inspection Techniques for Metal Cylinders .24 3.3 Review of Existing Inspection Techniques for Composite Cylinders .27 3.4 Applicability and Limitations of Various NDE Techniques to Specific Vessels 28 3.5 Metal Monobloc or Layered Vessels of Steel or Non

18、magnetic Alloys .29 3.6 Composite Hoop-Wrapped Vessels with Seamless or Welded Liners of Steel or Nonmagnetic Alloys 30 3.7 Composite Full-Wrapped Vessels with Seamless or Welded Liners of Steel or Nonmagnetic Alloys 31 3.8 Composite Full-Wrapped Vessels with Seamless or Welded Nonmetallic Liners an

19、d Metal Bosses of Steel or Nonmagnetic Alloys 31 3.9 Overall Recommendations.32 3.10 Recommendations for Inspection of All-Metal Cylinders at Manufacture 33 3.11 Recommendations for In-service Inspection of All-Metal Cylinders 33 3.12 Recommendations for Inspection of Composite Cylinders at Manufact

20、ure.34 3.13 Recommendations for In-service Inspection of Composite Cylinders.34 4 RECOMMENDED MARGINS FOR NEW CODE RULES .36 4.1 Factors Not Addressed by Margin to Burst .36 4.1.1 Pressure Control36 4.1.2 Material Degradation 37 4.1.3 Cyclic Fatigue.37 4.1.4 Fire Exposure37 4.1.5 Impact Damage to Co

21、mposites .37 4.2 Minimum Recommended Gas Cylinder Margins for Materials Not Susceptible to Creep, Stress Rupture, or External Impact Induced Fracture (Metals)38 4.3 Minimum Gas Cylinder Margins for Materials Susceptible to Creep, Stress Rupture, or Impact Induced Fracture (Composite Reinforced Cylin

22、ders) 38 4.3.1 Design of Composite Cylinders38 4.3.2 Recommended Margins for Types 3 and 4 Full-Wrapped Metal-Lined Designs Using Glass or Aramid Composite .41 4.3.3 Recommended Margins for Type 2 Hoop-Wrapped Designs.42 4.3.4 Recommended Margins for Type 3 and 4 Carbon Composite Vessels 44 4.3.5 Bu

23、rst Design Margins for Carbon Composite Designs.44 5 REQUIREMENT FOR SEPARATE DESIGN MARGINS FOR FATIGUE50 5.1 ASME Code Fatigue Rules50 5.2 DOT Composite Fatigue Margins50 5.3 DOT-3AA Metal Fatigue Margins.51 iv H2Standardization Interim Report STP/PT-003 5.4 NGV2 Fatigue Design Rules. 52 5.5 ISO F

24、uel Cylinder Fatigue Design Rules 53 5.6 ISO Metal Gas Cylinder Design Rules 53 5.7 ISO Composite Gas Cylinder Fatigue Design Rules. 54 5.8 ASME Code Case 2390-1 Fatigue Design Rules 54 6 EVALUATION OF MARGINS FOR 15,000 PSI METAL AND COMPOSITE VESSELS. 56 6.1 Use of Reference Standards 56 6.2 Desig

25、n Pressure Requirements 56 6.3 Design for 15,000 psi Metal Vessels. 56 6.3.1 ASME Minimum Burst Margin . 56 6.3.2 Critical Difference in High Pressure Design 57 6.3.3 Effect of Design Pressure on Recommended Minimum Margin . 57 6.3.4 Extrapolation of Reference Standards to 15,000 psi Operating Press

26、ure. 57 6.3.5 Wall Thickness of Ductile Metal Vessels for 15,000 psi Operating Pressure 58 6.3.6 Wall Thickness Concerns for Vessels Operating at 15,000 psi 60 6.3.7 Critical Conditions for Safe Application of Low Margins at 15,000 psi . 61 6.4 Design for 15,000 psi Composite Reinforced Vessels 63 6

27、.4.1 Potential Advantages of Composite Vessels for 15,000 psi. 63 6.4.2 Potential Disadvantages of Composites for 15,000 psi 64 7 REVIEW OF SCOPE, LIMITATIONS AND MODIFICATION OF EXISTING STANDARDS FOR LARGE AND SMALL 15,000-PSI VESSELS 66 7.1 Intended Scope of Modified Standards . 66 7.2 NOP or Ser

28、vice Pressure of New Hydrogen Transport Cylinders 66 7.3 Scope, Limitation, and Modifications for Ductile Metal 15,000-psi Vessels . 67 7.3.1 Inspection and Test Requirements . 67 7.3.2 ASME Section VIII Division 3 67 7.3.3 DOT-3AA/3AAX and ISO 9809/11120 Metal Gas Cylinder Standards . 68 7.4 Scope,

29、 Limitation, and Modifications for Composite Vessels 70 7.4.1 Designs for Code Composite Reinforced Vessels 70 7.4.2 Composite Material Characteristics and the Applicability of Metal Design Controls and Experience . 71 7.4.3 Composite Design 72 7.4.4 Composite Durability . 72 7.4.5 Developed Strengt

30、h of Composites 73 7.4.6 Performance Tests Relative to Composite Stress Ratios 73 7.4.7 Translation 73 7.4.8 Stress Rupture of Carbon Composites 74 7.4.9 Design Qualification by Similarity. 74 7.4.10 Resistance to Fracture of Carbon Composite Vessels 75 7.4.11 Inspection Capability for Carbon Compos

31、ite Cylinders 76 8 REVIEW OF EXISTING COMPOSITE CYLINDER STANDARDS FOR APPLICABILITY TO HYDROGEN STORAGE AT 15,000 PSI 77 8.1 Scope of Review 77 8.2 Requirements of Existing Composite Cylinder Standards and the Applicability to 15,000-psi Hydrogen Storage Vessels or Cylinders 77 8.2.1 General Requir

32、ements of Existing Composite Cylinders. 77 v STP/PT-003 H2Standardization Interim Report 8.2.2 Specific Present Composite Cylinder Standards.78 8.3 Review of Existing Standards for Composite Cylinders for Specific Applicability to 15,000 psi Hydrogen Storage Vessels85 8.3.1 Scope of New Vessels.85 8

33、.3.2 Scope of Present Composite Standards.85 8.3.3 Specific Present Composite Cylinder Standards.86 8.4 Review of Existing Standards for Composite Cylinders for Applicability to 15,000 psi Portable Hydrogen Cylinders.88 8.4.1 Scope of New Cylinders .88 8.4.2 Scope of Present Standards.88 8.4.3 Scope

34、 Issues with DOT FRP-1 and FRP-2 Cylinders.88 8.4.4 DOT CFFC .88 8.4.5 ISO Composite Gas Cylinder Standards.89 8.4.6 NGV289 8.4.7 ISO 11439 CNG Fuel Cylinders.89 8.4.8 ISO DIS 15869 Draft Standard for Hydrogen Vehicle Fuel Cylinders 89 8.4.9 ASME Code Case 2390 90 9 NECESSARY VESSEL INSTALLATION COD

35、ES .91 References - PART I.93 PART II - A Study of Existing Data, Standards, and Materials Related to Hydrogen Service (Storage and Transport Vessels).97 1 INTRODUCTION98 1.1 Background98 1.2 Scope of Report .98 1.3 Service Conditions.98 1.4 Executive Summary.98 2 ISSUES RELATED TO USING EXISTING ST

36、ANDARDS FOR HIGH-PRESSURE VESSELS .100 2.1 Metallic Vessels.100 2.1.1 Design Issues 101 2.1.2 Manufacturing Issues106 2.1.3 Testing Issues107 2.2 Composite Vessels.112 2.2.1 Design Issues 112 2.2.2 Manufacturing Issues112 2.2.3 Testing Issues112 3 SUCCESSFUL SERVICE DATA OF EXISTING VESSELS 120 3.1

37、Storage Vessels 120 3.2 Transport Tanks .120 3.3 Portable Cylinders120 3.4 Vehicle Fuel Tanks 120 4 EFFECT OF HIGH-PRESSURE HYDROGEN ON EXISTING COMMONLY USED MATERIALS .121 4.1 Existing Commonly Used Vessel Materials 121 vi H2Standardization Interim Report STP/PT-003 4.2 High-Pressure Hydrogen Expo

38、sure Degradation 121 4.2.1 Types of Hydrogen Embrittlement. 121 4.2.2 Metallurgical and Process Factors Affecting Hydrogen Embrittlement 122 4.3 Hydrogen Embrittlement Literature Review . 122 4.4 Recommended Metallic Materials For High-Pressure Hydrogen Service 131 4.4.1 Basis of Recommendations for

39、 Aluminum, Copper, Titanium, Nickel, and Stainless Steel Alloys 131 4.4.2 Basis of Recommendations for Carbon and Alloy Steels. 131 5 SUMMARY AND RECOMMENDATIONS 134 References - PART II . 136 Appendix A - Metallic Vessel Service Data. 138 Appendix B - Composite Vessel Service Data. 142 PART III - A

40、 Study of Existing Data, Standards and Materials Related to Hydrogen Service for Piping Systems and Transport Pipelines 147 1 INTRODUCTION . 148 1.1 Background . 148 1.2 Scope of Report. 148 1.3 Service Conditions 148 1.4 Executive Summary 148 2 EXISTING DESIGN PHILOSOPHY/EXPERIENCE 150 2.1 Piping D

41、esign Philosophy . 150 2.1.1 ASME B31.1 150 2.1.2 ASME B31.3 151 2.2 Pipeline Design Philosophy. 154 2.2.1 ASME B31.8 154 2.2.2 DOT Standard CFR Title 49 Part 192 154 2.2.3 Summary of Piping And Pipeline Standards 155 2.3 Piping Experience and Data 156 2.3.1 Design Criteria . 156 2.3.2 Service Data

42、. 156 2.3.3 In-Service Inspection and Safety 156 2.4 Pipeline Experience and Data 157 2.4.1 Design Criteria . 157 2.4.2 Service Data . 157 2.4.3 In-Service Inspection and Safety 157 3 EFFECT OF HYDROGEN ON COMMON MATERIALS 158 3.1 High-Pressure Hydrogen Exposure Degradation 158 3.1.1 Types of Hydrog

43、en Embrittlement. 158 3.1.2 Metallurgical and Process Factors Affecting Hydrogen Embrittlement 159 3.2 Hydrogen Embrittlement Literature Review . 159 3.3 Recommended Metallic Materials For High-Pressure Hydrogen Service 168 3.3.1 Basis of Recommendations for Aluminum, Copper, Titanium, Nickel and St

44、ainless Steel Alloys 168 3.3.2 Basis of Recommendations for Carbon and Alloy Steels. 168 vii STP/PT-003 H2Standardization Interim Report 4 FACTORS UNIQUE TO HIGH-PRESSURE HYDROGEN SERVICE 171 4.1 Surface Condition/Finish .171 4.2 Bending of Piping And Tubing172 4.2.1 Cold Bending 172 4.2.2 Hot Bendi

45、ng173 4.3 Piping Joints.174 4.3.1 Welded Joints174 4.3.2 Mechanical Joints .176 4.3.3 Dissimilar Metals178 5 DESIGN AND MATERIAL SELECTION RECOMMENDATIONS FOR HYDROGEN SERVICE .179 5.1 Piping Recommendations 179 5.1.1 Material.179 5.1.2 Design Margin 180 5.1.3 Fatigue Life.180 5.1.4 Leak Before Burs

46、t (LBB) .180 5.1.5 Welding and Welded Pipes.181 5.1.6 Pipe Fittings/Connections .181 5.1.7 Autofrettage 181 5.2 Pipeline Recommendations181 5.2.1 Pressure Limit.181 5.2.2 Design Margin 181 5.2.3 General Design Rules .182 5.2.4 Material.182 References - PART III 183 Appendix A - Design Margins and Pr

47、essure Ratios185 Appendix B - Mechanical Joint Information 189 Appendix C - Piping System Data 193 Appendix D - Pipeline Data196 ACKNOWLEDGMENTS 203 ABBREVIATIONS AND ACRONYMS .204 List of Tables Table 1 - Margin Comparison for Various Gas Cylinder and Vessel Standards 19 Table 2 - Requalification o

48、f Cylinders According to 48 CFR 180.209 25 Table 3 - Inspection Standards for All-Metal Cylinders Used in Hydrogen Service27 Table 4 - UT Inspection Requirements at Manufacture for Metal Cylinders .27 Table 5 - Summary of Advantages and Limitations of Inspection Techniques for All-Metal Cylinders.29

49、 Table 6 - Summary of Advantages and Limitations of Inspection Techniques for Hoop-Wrapped Cylinders.31 viii H2Standardization Interim Report STP/PT-003 Table 7 - Summary of Advantages and Limitations of Inspection Techniques for All-Composite Cylinders 32 Table 8 - Comparison of Fully Metallic Standards 109 Table 9 - Comparison of Composite Standards 116 Table 10 - Results of Tests in 10,000 psi Helium and in 10,000 psi Hydrogen . 126 Table 11 - Values of KHand Critical Flaw Depth 129 Table 12 - Material Recommendations for High-Pressure Hydrogen Gas. 132 Table 13 - Full Metallic Vessel Hyd