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Developers interested in high pressure storage of hydrogen for mobile use increasingly rely on composite cylinders for onboard storage or transport of dangerous goods. Thus, composite materials and systems deserve special consideration. History gives interesting background information important to the understanding of the current situation as to regulations, codes and standards.
Based on this review, origins of different regulations for the storage of hydrogen as dangerous good and as propellant for vehicles will be examined. Both categories started out using steel and sometimes aluminium as cylinder material. With composite materials becoming more common, a new problem emerged: vital input for regulations on composite pressure systems was initially derived from decades of experience with steel cylinders. As a result, both regulatory fields suffer somewhat from this common basis. Only recent developments regarding requirements for composite cylinders have begun to go more and more separate ways. Thus these differences lead to some shortcomings in regulation with respect to composite storage systems.
In principle, in spite of separate development, these deficits are in both applications very much the same: there are uncertainties in the prediction of safe service life, in retesting procedures of composite cylinders and in their intervals. Hence, different aspects of uncertainties and relevant approaches to solutions will be explained.
Gas cylinders made from composite materials receive growing popularity in applications where light weight is of advantage. At the same time manufacturers are interested in cutting cost and weight through material reduction for better acceptance of a product, e.g. H2-vehicles. This requires a better understanding of safety relevant properties.
The safety determination of current standards is mainly based on the minimum burst pressure of a few specimens. Various research projects were conducted aiming at reducing minimum burst pressure requirements without compromising safety. No satisfying results were found. While looking at reliability aspects it could be concluded, that the minimum burst pressure of unused specimens is not a satisfying criterion for safety during service life.
This paper introduces first ideas for a method to determine one aspect of reliability of composite gas cylinders, employing probabilistic analysis of burst pressures of a sample of specimens. This can create potential for saving material cost while granting a higher safety level than the current method. Additionally, degradation over service time can be assessed.