3.5 Sicherheit von Gasspeichern
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Degradation and damage analysis of composite pressure vessels via experimental modal analysis
(2023)
For mobile gas storage systems, the application of type IV pressure vessels is state of the art. Type IV tanks consist of an inner polymer liner fully wrapped with fibre-reinforced plastic (FRP). Because of the complex fabric of the FRP as well as a difficulty estimable interaction behaviour between the single components under load, there are still no satisfying non-destructive testing methods to assess the current state of failure nor to estimate the level of degradation accurately and economically. At BAM division 3.5, analysing the ageing process of mobile composite pressure vessels is a major task to ensure safe usage over the whole lifetime. In this context, key aspects of our ongoing research activities are the invention of new test procedures and the development of accurate lifetime prediction models. In order to determine the level of degradation or damage, one meaningful non-destructive approach is to analyse the structural dynamic behaviour via an experimental modal analysis (EMA). Over the last few years, different types and sizes of composite pressure vessels have been tested in several research projects. The presented paper gives an insight into how to extract and interpret modal parameters and how to fit them to the results of residual strength tests.
Degradation and damage analysis of composite pressure vessels via experimental modal analysis
(2023)
For mobile gas storage systems, the application of type IV pressure vessels is state of the art. Type IV tanks consist of an inner polymer liner fully wrapped with fibre-reinforced plastic (FRP). Because of the complex fabric of the FRP as well as a difficulty estimable interaction behaviour between the single components under load, there are still no satisfying non-destructive testing methods to assess the current state of failure nor to estimate the level of degradation accurately and economically. At BAM division 3.5, analysing the ageing process of mobile composite pressure vessels is a major task to ensure safe usage over the whole lifetime. In this context, key aspects of our ongoing research activities are the invention of new test procedures and the development of accurate lifetime prediction models. In order to determine the level of degradation or damage, one meaningful non-destructive approach is to analyse the structural dynamic behaviour via an experimental modal analysis (EMA). Over the last few years, different types and sizes of composite pressure vessels have been tested in several research projects. The presented paper gives an insight into how to extract and interpret modal parameters and how to fit them to the results of residual strength tests.
While hydrogen is one of the most promising energy carriers, the safety of hydrogen storage technology remains one of the most important factors for technological and societal approval. While the engineering safety factors of the pressure vessels are kept high, the periodic inspection and the limited lifetime are making the application very costly considering manpower, time, money, and material waste. The development of an integrated structural health monitoring system can allow an easy transition from the current situation to cost-effective predictive maintenance. Hence, we propose to integrate three different SHM systems into hydrogen pressure vessels, namely guided wave ultrasonics, acoustic emission, and fibre optic sensing, to continuously monitor the condition and integrity.
In this work, we evaluated the condition of a Type IV composite overwrapped pressure vessel using ultrasonic guided wave propagation. We mounted fifteen piezo-electric wafers on the composite cylinder by shaping three rings containing five sensors each. We acquired data from the sensor network following different boundary conditions with artificial damages on the selected locations. The data were evaluated with guided wave tomography techniques using ultrasonic features (amplitude, frequency, etc.) as well as artificial intelligence (AI). The results suggest that both traditional guided wave fusion techniques and AI-based characterization methods can detect artificial damages. In future work, it is planned to integrate acoustic emission and fibre optic sensing. Moreover, the measurement and the test results will be implemented into a digital twin to derive trends and make predictions on the damage propagation as well as the remaining useful lifetime.
This work has received funding from German Ministry of Economic Affairs and Climate Actions within the QI-Digital initiative (www.qi-digital.de).
We present the results of distributed fiber optic strain sensing for condition monitoring of a hybrid type IV composite fully wrapped pressure vessel using multilayer integrated optical fibers. Distributed strain sensing was performed for a total number of 252,000 load cycles until burst of the vessel. During this ageing test material fatigue could be monitored and spatially localized. Critical material changes were detected 17,000 cycles before material failure. Results have been validated by acoustic emission analysis.
Hydrogen is an attractive energy carrier that requires high effort for safe storage. Forensuring safety, they must undergo a challenging approval process. Relevant standardsand regulations for composite cylinders used for the transport of hydrogen and for its on-board storage are currently based on deterministic (e.g. ISO 11119-3) or semi-probabilistic(UN GTR No. 13) criteria. This paper analysis the properties of such methods withrespect to the evaluation of load cycle strength. Their characteristics are compared withthe probabilistic approach of the BAM. Based on Monte-Carlo simulations, the availabledesign range (mean value and scatter of strength criteria) of current concepts was exem-plarily estimated. The aspect of small sample sizes is analysed and discussed with respectto the evaluation procedures.