Determination of the intervals of periodic inspections for composite pressure receptacles

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1 EN Determination of the intervals of periodic inspections for composite pressure receptacles executed by the competent authority according to RID/ADR/IMDG-Code P 200 (8), also including IATA-Dangerous goods regulations. Procedural method The English translation of this document has been carefully reviewed. However, only the German version can be regarded as legally binding. The procedure specified within this document is suited for the determination of the intervals of periodic inspections for composite pressure receptacles in Germany as compulsory by the regulations relevant for the multimodal transport of dangerous goods. It particularly pays attention to the multitude of design variables and the complexity of the characteristics of composite pressure receptacles designed in accordance with accepted standards. Thereby the special properties of the composite construction regarding service life analysis and periodic inspection testing are notably recognised. The provided procedural method replaces the previous procedure of (version 3.1). Contact: RegDir Dr. Georg W. Mair Dr.-Ing. Jost-Peter Sonnenberg Dipl.-Ing. Markus Lau version 4.0 (English translation) released on Safety and reliability in chemical and materials technologies

2 Intervals of periodic inspection for composite pressure receptacles Procedural method version 4.0 EN, released on Contents 1 Concept description Fundamentals on the determination of the intervals of periodic inspections Legal basis of the action Responsibility of the Federal Institute for Materials Research and Testing Scope Safety goal Regulation stipulating the safety goal to be achieved Conjunction with other regulations and standards Determination of inspection intervals for new designs Preface Maximum obtainable inspection intervals Requirements for the determination of inspection intervals (Annex A) Re-determination of the intervals of periodic inspections Preface Criteria for the re-determination of the intervals of periodic inspections...7 Annex A: Tables of requirements of Annex B: Additional tests Description of tests (being developed) page 2 of 7

3 Intervals of periodic inspection for composite pressure receptacles Procedural method version 4.0 EN, released on Concept description 1.1 Fundamentals on the determination of the intervals of periodic inspections Pressure receptacles made of composites are mechanical structures with a variety of design parameters which are unknown in conjunction with steel cylinders. Dependent on the type of the liner, on fibre type and layer setup the relevant attributes suitable for the determination of a safety-related inspection interval may vary significantly. Therefore the inspection intervals of composite receptacles for application with dangerous goods are not determined on a basis of the transported substance (as described in RID/ADR P 200). Instead the determination of the intervals of periodic inspections has to be conducted by the competent authority for each design type individually. In Germany the Federal Institute for Materials Research and Testing (BAM) is obliged to fulfil this task in coordination with the Zentralstelle der Länder für Sicherheitstechnik (ZLS). The present process is agreed between BAM and ZLS and is conducted by the BAM. It has been common practice in Germany that new design types were initially assigned to an inspection period of 3 years. Later on, with positive in-service experience these intervals were extended. However with increasing expertise on these kinds of pressure receptacles it is now assumed that an inspection period of 5 years should be considered as state-of-theart, whereas a period of 10 years should be an exception. Nevertheless the determination of an inspection interval of 3 years is still consistent in cases where the standard procedures of the design approval are not sufficient for a review of the safety characteristics of the design without additional effort. With the present revision of the requirements for the determination of inspection intervals it is now possible to obtain longer (which means > 3 years) intervals of periodic inspection right in conjunction with the design approval. This document now reflects the most common case that an interval of periodic inspections is applied for directly in connection with the approval of the respective design, just as it is prescribed in the regulations. 1.2 Legal basis of the action According to RID/ADR/ADN P200 (9) the intervals of periodic inspections for composite pressure receptacles are not tabularly listed, but are left open to be determined by a competent authority to the respective design. A comparable rule is not existent in any other international regulatory document on the transport of dangerous goods. The IMDG Code adopts the text of the UN model regulations, whereas the IATA Dangerous goods regulations imply a direct reference to the UN model regulations. Within the UN model regulations there is no periodic inspection for composite pressure receptacles, but rather a direct limitation of the service life of the receptacles with an option of an extension of the usage permitted by the competent authority. Moreover the IMDG Code leaves the option of applying national regulations, which again makes it possible to use the requirements of the RID/ADR/ADN instead. page 3 of 7

4 Intervals of periodic inspection for composite pressure receptacles Procedural method version 4.0 EN, released on Responsibility of the Federal Institute for Materials Research and Testing The responsibility of BAM in Germany is laid down within the following laws and provisions: 6 Abs. 2 Nr. 24 and 25 of Gefahrgutverordnung Straße und Eisenbahn (GGVSE) as amended and promulgated on Abs of RSE Richtlinien zur Durchführung der GGVSE as of Abs. 5 of Gefahrgutverordnung See (GGVSee) as of , particularly in conjunction with chapter P200 (2) of the IMDG Code (Amdt ), as announced in the official translation of (VkBl. 2006, S. 844) Section und in conjunction with F.2 of the IATA Dangerous Goods Regulations 2008 (49 th edition) 1.4 Scope This document is applicable to pressure receptacles of composite construction which are designed, approved and tested in accordance with the standards referred to within RID/ADR/ADN. In detail, the following standards are appropriate: EN 12257:2002 Hoop-wrapped composite cylinders DIN EN 12245:2002 Fully wrapped composite cylinders with and without loadsharing liners EN 14427: A1:2005 Fully wrapped composite cylinders for LPG ISO : 2002 Hoop-wrapped composite cylinders ISO : 2002 Fully wrapped composite cylinders with load-sharing liners ISO : 2002 Fully wrapped composite cylinders without load-sharing liners 1.5 Safety goal The safety goal implies an unlimited protection against infringement of health and property of the owner, the occupant, the operator and of uninvolved bystanders during the unaffected proper use. 1.6 Regulation stipulating the safety goal to be achieved The intervals of periodic inspections of composite pressure receptacles are to be determined in line with the state-of-the-art, or with the state-of-the-art of science and technology where applicable, such that an unbearable residual risk occurs neither during intense usage (frequent refills) nor due to the abandonment of the usage (no refill after transport or a falling into oblivion after a partial emptying). Special attention is given to the case of a spontaneous burst. page 4 of 7

5 Intervals of periodic inspection for composite pressure receptacles Procedural method version 4.0 EN, released on Conjunction with other regulations and standards The determination of the intervals of periodic inspections in all cases is only carried out considering the safety requirements connected to the transport of dangerous goods in composite pressure receptacles by road and rail. Therefore only safe transport conditions are considered. In case the receptacles are used under significantly different circumstances (e.g. temporary or permanent usage in facilities with different operating parameters like filling procedures, filling frequency), additional provisions of other regulations might apply. This may cause additional tests, shorter inspection intervals or differently calculated service lives to become necessary. Provisions not concerning the transport of dangerous goods are not reviewed and evaluated for the notifications of the intervals of periodic inspections. 2 Determination of inspection intervals for new designs 2.1 Preface For all new designs of composite pressure receptacles, an interval of periodic inspections has to be determined by the competent authority in connection with the placing on the market. This determination has to be conducted at any case. However, the determination by the BAM is only carried out on application of the manufacturer, the trader or an authorised notified body (according to Directive 1999/36/EC). The submission of the design approval documents without any supplemental tests is sufficient for the assignment of an interval of periodic inspections of 3 years. For the application for longer inspection intervals additional verifications are demanded with regard to the fatigue characteristics of the respective receptacles. Concerning the additional proof it is distinguished between pressure receptacles with load-sharing liners and pressure receptacles without load-sharing liners. Detailed information on the respective supplemental tests can be gathered from section 2.3 and 2.4 of this document in connection with Annex A. Different from this section, for pressure receptacles with more than three years of in-service experience also the procedure of chapter 3 of this document can be utilized for the obtaining of an inspection interval of 5 or 10 years. 2.2 Maximum obtainable inspection intervals The strictly maximal allowable interval of periodic inspections for composite pressure receptacles amounts to not longer (no more years) than that interval which is scheduled for equivalent steel cylinders for the transport of the respective dangerous good (UN number) according to P200 RID/ADR, 5 years for pressure receptacles consisting of glass fibre reinforced plastics. Cylinders intended solely for LPG applications are considered suitable for an interval of 10 years also, 5 years for pressure receptacles employing aramid or carbon fibres which have been certified (1999/36/EC) or approved (IMDG Code) for a limited service life of less than 20 years, 10 years for pressure receptacles employing aramid or carbon fibres which have been certified (1999/36/EC) or approved (IMDG Code) for a limited service life of not less than 20 years or for unlimited life, page 5 of 7

6 Intervals of periodic inspection for composite pressure receptacles Procedural method version 4.0 EN, released on years exclusively for pressure receptacles which have proven fail-safe properties (e.g. pressure receptacles with load-sharing liners, in particular hoop-wrapped receptacles) or for which a comparably low hazard potential in case of an accident has been comprehensively proved. 2.3 Requirements for the determination of inspection intervals (Annex A) The definite criteria for the determination of the intervals of periodic inspections, dependent on the construction standards and the aspired intervals are laid down in the tables of Annex A to this document. There are separate tables for hoop-wrapped pressure receptacles (Table A.1; ISO , EN 12257), fully-wrapped pressure receptacles with load-sharing liners (Table A.2; ISO , EN 12245), and fully wrapped pressure receptacles without load-sharing liners (Table A.3; ISO ; EN 12245; EN14427 not cross-referenced), in which the basic (consistent with the standard) and the supplemental tests for the aspired inspection interval (3, 5 or 10 years) are listed. Essential characteristics of the supplemental tests can be found in the applicable footnotes, where also the required number of specimens is listed. All tests are to be conducted under the supervision of a notified body. Remarks: The manufacturer or the owner of the receptacles, or an authorised notified body may submit an application for the determination of an interval of periodic inspections to the BAM. It is highly recommended to coordinate the test program for the inspection intervals of 5 and 10 years with BAM prior to testing. Upon submission of all required test reports (tests according to the design standard and supplemental tests, if applicable) and typically the corresponding certificates according to Directive 1999/36/EC, BAM as the German competent authority will issue the applied interval of periodic inspections, as long as the requirements of Annex A are fulfilled. page 6 of 7

7 Intervals of periodic inspection for composite pressure receptacles Procedural method version 4.0 EN, released on Re-determination of the intervals of periodic inspections 3.1 Preface Manufacturers or operators of composite pressure receptacles that are already in use have the possibility to make application for a re-determination for the intervals of periodic inspections. Hereby it is irrelevant whether the design is still manufactured or the circulating stock is addressed. Within this section it is listed how it is to be proceeded in such cases. The following principles are valid for the re-determination of inspection intervals: a) The re-determination of the inspection intervals are based on the same safety-related considerations as the initial determination (see section 2) b) The primary goal of the re-determination of the inspection interval therefore is the proof of an equivalent safety level of the pressure receptacle subject to the assessment. Upon request this can also be accomplished incorporating the field experience with the corresponding pressure receptacles c) Due to the multitude of possibilities to imply the operating experience for the redetermination of the inspection intervals, a definite procedure is not formulated. 3.2 Criteria for the re-determination of the intervals of periodic inspections For an extension of the inspection intervals of pressure receptacles that are already in use it is generally intended to carry out the procedure of section 2 of this document according to the aspired interval. The required specimens can be taken directly out of the production of the same design type as laid down in the standards. If they are not available, or they are not to be used, also a representative sample out of the circulation may be used. As an alternative approach, in agreement with BAM also the results of previous periodic inspections and other field experience can be utilised to support an equivalent safety level compared to the tests laid down in Annex A. For this purpose, at least three years of practical experience are needed. The operating conditions of such test samples must be known and documented and also representative for the use of the respective design. page 7 of 7

8 DE / EN Festlegung der Prüffristen von Druckgefäßen aus Verbundwerkstoffen Determination of the intervals of periodic inspection of composite pressure receptacles Anlage A: Anforderungstabellen Enclosure A: Tables of requirements Anlage zur Verfahrensbescheibung Festlegung der Prüffristen von Druckgefäßen aus Verbundwerkstoffen vom Enclosure to the process description Determination of the intervals of periodic inspection of composite pressure receptacles as of (German version available only) Ansprechpartner: Contact: RegDir Dr. Georg W. Mair Dr.-Ing. Jost-Peter Sonnenberg Dipl.- Ing. Markus Lau Version 1.1 vom 6. Januar 2009 from Sicherheit in Technik und Chemie

9 Retesting periods - enclosure A: Tables of requirements 6 th January 2009 A.1 Tabelle zu den Anforderungen für umfangsumwickelte Druckgefäße Table on the requirements for hoop-wrapped pressure receptacles In Anlehnung/following ISO :2002 und/and EN 12257:2002 Bezeichnung der Prüfung Test designation Referenz /Reference ISO Prüffrist /Retesting period EN a 5 a 10 a Prüfungen nach Baumusterzulassung /Tests according to the design approval Liner material tests Overwrap material tests Hydraulic proof pressure test/ volumetric expansion (ISO only) Liner burst test Cylinder burst test Ambient cycle test s. ACF s. ACF Environmental cycle test s.htc s.htc+ +ACF LCF/HCF High velocity impact test 1) Fire resistance test 1) Salt water immersion test 1) Torque test High temp creep test (w.burst) 1) Drop test 1) Neck strength test 1) Cylinder stability test 1) Neck ring test 1) Ergänzende Prüfungen /Additional tests Ambient cycle test to failure Zyklieren bei Umgebungstemperatur bis zum Versagen ACF High temp. conditioning 4) with ambient cycle test to failure HTC + Hochtemperaturkonditionierung mit anschließendem ACF Umgebungstemperaturzyklieren bis zum Versagen High temp. conditioning 4) with low temperature cycle test to failure Hochtemperaturkonditionierung mit anschließendem Tieftemperaturzyklieren bis zum Versagen High temp. conditioning 4) with high temperature cycle test to failure Hochtemperaturkonditionierung mit anschließendem Hochtemperaturzyklieren bis zum Versagen Betriebsbegleitende Prüfungen /In-service tests 6) 7) Residual burst pressure test Restberstdruckprüfung 6) 8) Residual life cycle test Restlastwechselzahlprüfung HTC + LCF HTC + HCF RBP RL A 2 / 5

10 Retesting periods - enclosure A: Tables of requirements 6 th January 2009 A.2 Tabelle zu den Anforderungen für vollumwickelte Druckgefäße mit mittragendem Liner Table on the requirements for fully-wrapped pressure receptacles with load-sharing liner In Anlehnung/following ISO :2002 und/and EN 12245:2002 Bezeichnung der Prüfung Test designation Referenz /Reference ISO Prüffrist /Retesting period EN a 5 a 10 a Prüfungen nach Baumusterzulassung /Tests according to the design approval Liner material tests Composite material tests Hydraulic proof pressure test/ volumetric expansion (ISO only) Liner burst test Cylinder burst test Ambient cycle test s. ACF s. ACF Environmental cycle test s. HTC s. HTC+ +ACF LCF/HCF Flaw test High velocity impact test Fire resistance test 1) Salt water immersion test 1) Torque test High temp. creep test (w. burst) Drop test Neck strength test 1) Cylinder stability test 1) Neck ring test 1) Ergänzende Prüfungen /Additional tests Ambient cycle test to failure Zyklieren bei Umgebungstemperatur bis zum Versagen ACF High temp. conditioning 4) with ambient cycle test to failure HTC + Hochtemperaturkonditionierung mit anschließendem ACF Umgebungstemperaturzyklieren bis zum Versagen High temp. conditioning 4) with low temperature cycle test to failure Hochtemperaturkonditionierung mit anschließendem Tieftemperaturzyklieren bis zum Versagen High temp. conditioning 4) with high temperature cycle test to failure Hochtemperaturkonditionierung mit anschließendem Hochtemperaturzyklieren bis zum Versagen Betriebsbegleitende Prüfungen /In-service tests 6) 7) Residual burst pressure test Restberstdruckprüfung 6) 8) Residual life cycle test Restlastwechselzahlprüfung HTC + LCF HTC + HCF RBP RL A 3 / 5

11 Retesting periods - enclosure A: Tables of requirements 6 th January 2009 A.3 Tabelle zu den Anforderungen für vollumwickelte Druckgefäße ohne mittragendem Liner Table on the requirements for fully-wrapped pressure receptacles without load-sharing liner In Anlehnung/following ISO :2002 und/and EN 12245:2002 Bezeichnung der Prüfung Test designation Referenz /Reference ISO Prüffrist /Retesting period EN a 5 a 10 a Prüfungen nach Baumusterzulassung /Tests according to the design approval Liner material tests Composite material tests Hydraulic proof pressure test/ volumetric expansion (ISO only) Cylinder burst test Ambient cycle test s. ACF s. ACF Vacuum test 1) Environmental cycle test s. HTC+ ACF + s. HTC+ HCF High temp. creep test (w. burst) Flaw test Drop test High velocity impact test Fire resistance test 1) Permeability test Torque test Salt water immersion test 1) Leak test 1) Pneumatic test 1) Water boil test 1) Neck strength test 1) Cylinder stability test 1) Neck ring test 1) Ergänzende Prüfungen /Additional tests Ambient cycle test to failure Zyklieren bei Umgebungstemperatur bis zum Versagen ACF High temp. conditioning 4) with ambient cycle test to failure Hochtemperaturkonditionierung mit anschließendem Umgebungstemperaturzyklieren bis zum Versagen High temp. conditioning 4) with high temperature cycle test to failure Hochtemperaturkonditionierung mit anschließendem Hochtemperaturzyklieren bis zum Versagen High temp. creep test to failure 5) Hochtemperatur-Kriechprüfung bis zum Versagen Betriebsbegleitende Prüfungen /In-service tests Residual burst pressure 6) 7) test Restberstdruckprüfung Residual life cycle 6) 8) test Restlastwechselzahlprüfung A 4 / 5 HTC + ACF HTC + HCF HTCF RBP RL

12 Retesting periods - enclosure A: Tables of requirements 6 th January 2009 Erläuterung der Fußnoten 1) 2) 3) 4) 5) 6) 7) 8) Diese Prüfungen sind nur dann notwendig, wenn sie gemäß der Norm für die betreffende Bauart vorgeschrieben sind. Diese Prüfung ist immer bis zum Versagen des Prüflings durch Ermüdung fortzusetzen. Die Lastwechselzahlen sind aufzuzeichnen. Ein Abbruch ist erst nach Lastwechseln statthaft. Die Prüfung findet bei Umgebungstemperatur (ACF: 20 C), Tieftemperatur (LCF: 40 C) oder Hochtemperatur (HCF: 65 C) statt und ist an zwei Prüflingen durchzuführen. Als Mindestlastwechselzahl bis zum Versagen (Leckage) ist die erwartete Befüllungszahl pro Jahr mit der Lebensdauer des Druckgefäßes in Jahren sowie dem Faktor 10 zu multiplizieren. In jedem Fall sind mindestens 250 Lastwechsel pro Jahr anzunehmen. Die Prüflinge sind vor der Lastwechselprüfung einer Temperatur-Konditionierung bei Prüfdruck (hydraulisch) und mindestens 65 C zu unterwerfen. Die Dauer der Konditionierung beträgt 100 Stunden multipliziert mit der Lebensdauer des Druckgefäßes in Jahren. Die Prüfung ist jeweils an zwei Druckgefäßen durchzuführen. Die Prüfung ist nach Anlage CRL durchzuführen Nach Ablauf der ersten Prüfperiode sind repräsentativ genutzte Druckgefäße den Prüfungen der Restfestigkeiten zuzuführen. Ein Abfall des Berstdrucks ist bis zum Ende des Lebens bis auf maximal 85% des Ausgangsberstdrucks gestattet. Entsprechend ist die erlaubte Abnahme des Berstdrucks proportional zur Gesamtlebensdauer zu berechnen. Die Restlebensdauer ist nach dem für die Prüffristenfestlegung festgelegten Verfahren (ACF) zu überprüfen. Die erlaubte Abnahme der Lebensdauer ist proportional zur Gesamtlebensdauer zu berechnen. Bezugslastwechselzahl ist dabei die bei der Prüfung ACF am neuen Behälter ermittelte Lastwechselzahl nach 3). Explanation of the footnotes 1) 2) 3) 4) 5) 6) 7) 8) These tests are only required if they are obligatory in the standard used for the manufacture of the respective design type. The test has to be continued up to the fatigue failure of the specimen in all cases. The number of fatigue cycles has to be recorded. The test may be aborted after 50,000 load cycles. This test must be conducted at ambient conditions (20 C), cold temperature conditions (< 40 C) or high temperature conditions (> 65 C), as applicable, with two samples. The required number of cycles to failure is calculated as follows: Number of expected in-service fillings per year times lifetime of the receptacle in years times a factor of ten. As a minimum, 250 life cycles per year must be assumed. Before cycling, the samples have to be conditioned at test pressure (hydraulic) and a temperature of at least 65 C. The duration of the conditioning must be 100 hrs per years of lifetime of the receptacles. The test has to be conducted with two samples. This test has to be conducted in accordance with enclosure CRL. After the first retesting period the residual strength tests have to be conducted with a representative sample of the pressure receptacles of the respective design type. A decrease of the burst pressure is allowed down to 85% of the initial burst pressure at the end of the lifespan. The allowed decrease of burst pressure for the respective time span has to be calculated proportionally to the allowed decrease within the total lifespan. The residual fatigue life has to be determined in accordance with the test procedure ACF described within this document. The allowed decrease in cycling fatigue life within the given time span has to be calculated proportionally to the initial number of life cycles which has been given in 3). A 5 / 5

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