MATHRYCE Workshop

Paris, September 18th 2015

MATHRYCE D2.6
Fatigue life analysis of a H2 pressure
vessel according to ASME PVP Sec.
VIII, Divs. 2 & 3, EN13445, KHKS 0220
Jader Furtado, Takuya Matsumoto (Air Liquide),
Paolo Bortot (TenarisDalmine)
Laurent Briottet (CEA)
Randy Dey (CCS)
1

Outline
Introduction & aim of the work
Are design codes prepared for the H2-based economy?
Hydrogen-enhanced fatigue according to codes and standards:
Case study
ASME PVP Section VIII Div.2
ASME PVP Section VIII Div. 3 KD-10
EN13445
KHKS 0220
Codes comparison
Conclusions and recommendations

Introduction
In hydrogen refueling stations, a key issue is to control the
possibility of hydrogen-enhanced fatigue of metallic stationary
reservoirs.
But, before tackling this problem, how do existing codes and
standards treat hydrogen-enhanced fatigue issue in the design
phase of a project?

Aim
To carry out a fatigue assessment, based on a selected case study,
comparing the main international standards for pressure vessels
design.

Outline
Introduction & aim of the work
Are design codes prepared for the H2-based economy?
Hydrogen-enhanced fatigue according to codes and standards:
Case study
ASME PVP Section VIII Div.2
ASME PVP Section VIII Div. 3 KD-10
EN13445
KHKS 0220
Codes comparison
Conclusions and recommendations

Are design codes prepared for the H2-based economy?

Storage types and cycling patterns
Vessel types
Cycles families

Mobile vessels: Cylinders, bundles and tube trailers

Onboard vessels: Automotive, public transport, material handling (forflifts)
Stationary vessels: Buffer tanks of hydrogen fueling stations
Deep cycles
Shallow cycles

P
Test pressure

Deep cycles
[Mobile vessels,
onboard vessels]

H2

Working
pressure

Shallow cycles
[Stationary vessels]

Pmax

H2

Pmin

low P

Experimental specifications
(for lab-scale & full scale tests)

Operational
conditions

April
2013

Air Liquide
R&D / CRCD

Are design codes prepared for the H2-based economy?

Standard and code

country

Design Rule

Service life (Number of cycle)

AD 2000-Merkblatt

Germany

Prescriptive formula for

minimum wall thickness

S-N approach

EN 13445

EC

Prescriptive formula for

minimum wall thickness

S-N approach

ASME Section VIII,

Div. 1/2

USA

Prescriptive formula for

minimum wall thickness

S-N approach

France

Prescriptive formula for

minimum wall thickness

CODAP

S-N approach

Prescriptive formula for

Yes, depending on fracture
minimum wall thickness or
mechanics calculations (according
elastic-plastic analysis (according
to KD-10)
to KD-2)
Design life based on fatigue
Follows the approach of ASME analysis based on S-N curves and
section VIII, Divs. 1, 2, 3
crack growth analysis similar to
KD-10

ASME Section VIII,

Div.3

USA

KHK S 0220

Japan

ISO11114-4

International

Not for design.

CSA-CHMC1

Canada

Not for design.

Special requirements for H2

gas
Considered through a safety
factor of 10 on the number
of cycles
H2 isnt considered
H2 isnt considered

Recommendations : max
UTS 950 MPa
(Low alloyed Steels)
Yes, through KD-10 article
Crack propagation

H2 isnt considered
Selection of materials for
Hydrogen use (3 methods)
Selection of materials for
Hydrogen use (fatigue tests)

How do they consider H2-enhanced fatigue crack initiation and

propagation?
6

Outline
Introduction & aim of the work
Are design codes prepared for the H2-based economy?
Hydrogen-enhanced fatigue according to codes and standards:
Case study
ASME PVP Section VIII Div.2
ASME PVP Section VIII Div. 3 KD-10
EN13445
KHKS 0220
Codes comparison
Conclusions and recommendations

Case study
Geometry

220x9.1 mm
(ODxWT min)

Steel

34CrMo4
YS min = 600 MPA
780 < UTS < 890 MPa

Current design standard

EN-1964-1
+
2010/35/EU
(TPED
qualification);
MAWP = 28 MPa;
No requirements on HE since UTS<950
MPa.

Different codes were used for comparing fatigue life assessment:

ASME Section VIII Div.2
ASME Section VIII Div. 3 art. KD-10
EN13445
KHKS 0220.

ASME Section VIII Div. 2

Static Calculation
ASME Sec. VIII Div.2
Material

Actual mechanical
Properties

SA372-Gr J Cl.70
(equivalent ASME material but with
lower mechanical properties)

WT = 9.1 mm

YS min = 600 MPa

780 < UTS < 890 MPa

Under the assumption to use the actual mechanical properties, which are not currently
admitted by ASME code
Equivalent design from a static point of view

ASME Section VIII Div. 2

Fatigue life calculation (2-28 MPa)
FE stress analysis and determination of the critical point for fatigue investigation.
Stress categorization for determination of Sa;
Determination of the allowable number of cycles:

N = 1,851,566 cycles
10

ASME Section VIII Div. 3, art. KD-10*

1. Initial crack size
Semielliptical crack shape:
Initial crack depth a = 0.5 mm;
Initial crack length 2c = 3a (prescribed by KD-10).
2. Stress intensity factor solution
KCSCLE1 - Cylinder surface crack, longitudinal direction - semi elliptical shape,
pressure solution was selected for this case.

KI =

internal

2
3
4

a a
a
a
a
2G0 2G1 + 3G2 4G3 + 5G4
R
R
R
R
2
Q
Ri
i
i
i
i
2

pR0
2

R0

ASME Section VIII Div. 3 art. KD-10 is mandatory only for MAWP exceeding 41 MPa

11

ASME Section VIII, Div. 3, art. KD-10

3. FCGR Curve
da
= CKm
dN

Pressure range was considered 20-280 bar (R=0.071).

FCGR data were taken from [1] from a SCM435 steel with YS=700 MPa and UTS=828 MPa.

da
3.07
= 3.48x1012 (K )
dN
= 7.12p0.343

da/dN data in air

da
dNH2
=
da
dNair

Effect of pressure on da/dN

Using the previous equation, FCGR constants were determined for a MAWP=28 MPa.

da
3.07
= 8x1011(K )
dN

in 28 MPa H2 gas

[1] Yamabe et al., Fatigue Life and leak before break assessments of Cr-Mo steel pressure vessels with high pressure gaseous hydrogen, PVP2014-28604

12

ASME Section VIII, Div. 3, art. KD-10

4. Threshold stress intensity factor calculation
Fracture toughness values were obtained on two SCM 435 steels[1] under rising load conditions
at p=45 MPa.
A lower bound KIH=64 MPa*m1/2 was obtained.
Rising load conditions are known to be more conservative than crack arrest conditions.

[1] Yamabe et al., Fatigue Life and leak before break assessments of Cr-Mo steel pressure vessels with high pressure gaseous hydrogen, PVP2014-28604

13

ASME Section VIII, Div. 3, art. KD-10

5. Allowable final crack size
Critical crack depth is calculated using the FAD (failure assessment diagram).
If the critical crack depth is less than the wall thickness it cannot be assumed that a LBB will
occur.

API 579-1/ASME FFS 2007

From [1]

[1] Somerday et al. Measurement of fatigue crack growth rates for SA-372 Gr. J steel in 100 MPa hydrogen gas following article KD-10,
PVP2013-97455

14

ASME Section VIII, Div. 3, art. KD-10

Output: Determination of the number of cycles and failure mode
Allowable number of
cycles
Air

104,000

H2

4500
From [1]

LBB occurs if both the following conditions are met:

1. the maximum stress intensity factor for a crack with a/t = 0.8 is less than KIC.
2. the remaining ligament is smaller than (KIC/Y)2, where Y is the YS of the used material.
LBB was verified.
[1] Somerday et al. Measurement of fatigue crack growth rates for SA-372 Gr. J steel in 100 MPa hydrogen gas following article KD-10,
PVP2013-97455

15

Outline
Introduction & aim of the work
Are design codes prepared for the H2-based economy?
Hydrogen-enhanced fatigue according to codes and standards:
Case study
ASME PVP Section VIII Div.2
ASME PVP Section VIII Div. 3 KD-10
EN13445
KHKS 0220
Codes comparison
Conclusions and recommendations

16

EN 13445
Static Calculation
EN 13445
Material

34CrMo4 (1.7220) EN 10083-1:2006

WT = 9.1 mm

Actual mechanical
Properties

YS min = 600 MPa

780 < UTS < 890 MPa

17

EN 13445
Fatigue life calculation (2-28 MPa)
FE stress analysis and determination of the critical
point for fatigue investigation.
Stress categorization for determination of Sa;
Determination of the allowable number of cycles:
Fatigue assessment is based on effective equivalent
total stress, considering the effective stress
concentration factor .

N = 173,551 cycles
18

KHK-S-0220 design methodology

Start
Define design specification
pressure part design, material, design pressure, design temperature,
working pressure, working temperature, design life (service life)
Material testing
Tensile test, charpy impact test
Calculate computational thickness, tr, and maximum allowable pressure, Pall
Confirm design thickness is smaller than tr and design pressure is smaller than Pall
Calculate allowable design life, Na, by fatigue analysis

Fatigue analysis
Confirm design life is smaller than Na
Damage tolerance analysis

No
Satisfaction of LBB

Yes

Calculate allowable design life, Na, by

fatigue crack growth analysis
Confirm design life is smaller than Na

End
19

Allowable design life, Na, by fatigue analysis in air (1)

S alt =

K 1
2

(Pu

Pl )

Where
Salt : Stress amplitude
Pu : Maximum working pressure = 28 MPa
Pl : Minimum working pressure = 2 MPa
Salt = 164.8 MPa

'

alt

= S

alt

Ed

Pall =

2 (S y + S u )
ln K
2
3f

Pall: Maximum allowable pressure

Di : Inner diameter
D0 : Outer diameter
K : Ratio of inner diameter and outer
diameter, D0/Di
f : Safety factor (2.4)
Sy : Yield strength
Su : Tensile strength

Where
E/Ed: Ratio of modulus of elasticity = 1.020 (depends on material and working
temperature)
: Stress intensity factor by surface roughness = 1 (If Rz is less than 3.2 m)
Salt = 168.1 MPa

20

Allowable design life, Na, by fatigue analysis in air (2)

Stress amplitude ((MPa)

Design life shall be less than Na of 255,714 cycles

168.1

Number of cycles

Na = 255,714

Note 1. Dashed line: tensile strength is less than 550 MPa

2. Solid line: tensile strength is 790 MPa to 895 MPa

Design fatigue curves of carbon steel, low alloy steel and ferirtic stainless steel
(Tensile strength is less than 895 MPa at RT)
21

Satisfaction of LBB
Start

Criteria to be satified:

Define design specification

pressure part design, material, design pressure, design temperature,
working pressure, working temperature, design life (service life)

< K

1)

2)

0 .2 t < (K IC S y )

IC
2

Where
KI: Stress intensity factor
KIC: Plain strain fracture toughness
KI shall be calculated on crack depth of 0.8t

Material testing
Tensile test, charpy impact test

Calculate computational thickness, tr, and maximum allowable pressure, Pall

Confirm design thickness is smaller than tr and design pressure is smaller than Pall

t
Calculate allowable design life, Na, by fatigue analysis
Confirm design life is smaller than Na

a =0.8t
l
Aspect ratio: a/l = 1.3

No
Satisfaction of LBB

Yes

Calculate allowable design life, Na, by

fatigue crack growth analysis
Confirm design life is smaller than Na

End

22

Satisfaction of LBB
Calculation of KI

K I = (A0 + Ap )G0 + A1G1 + A2G2 + A3G3 a Q

Q = 1 + 4 .593 (a l )

1 .65

Where
A0 ~ A3: Coefficients
Ap: Pressure on crack surface (= 28 MPa)
Q: Parameter on crack shape
G0 ~ G3: Free surface correction factor
a/l: Aspect ratio (= 1/3)
a: Crack depth (= 0.8t)
l: Crack length (= 2c)
c: Half crack length
Q = 1.74

23

Satisfaction of LBB
Calculation of KI
Calculation of A0 ~ A3
Stress distribution, , is approximated by the following equation

= A0 + A1 (x a) + A2 ( x a)2 + A3 (x a)3
Where x is distance from surface (0 x a)
If stress is only generated by pressure and K is in the range of 1.2 K 3, stress
distribution is approximated by the following equation.

= A'0 + A'1 (x t ) + A' 2 (x t )2 + A'3 (x t )3

Calculation of G0 ~ G3

K I = (A0 + Ap )G0 + A1G1 + A2G2 + A3G3 a Q

24

Satisfaction of LBB
Calculation of KI
KI = 47.2 MPam1/2
Determination of KIC from KHK
database
KIC = 200 MPam1/2
Verification if LBB is satisfied

LBB is satisfied.

Obtained from the figure or calculated by using the equation

(CVN = 150 J)

25

Design life, Nf, by fatigue crack growth analysis

Equations for the calculation

K I = (A0 + Ap )G0 + A1G1 + A2G2 + A3G3 a Q

Q = 1 + 4 .593 (a l )

1 .65

da dN = Cf (R )K I

f (R ) = 1 + C 3 R

Fixed values

Pressure range: 2 28 MPa

Dimensions of the cylinder: Tenariss design
Aspect ratio: a/l = 1/3
f (R) = 1 + 3.53 x 2/28 = 1.25
Critical crack depth: ac = 0.8t = 7.24 mm
Initial crack depth: 0.500 mm (defined by the code but depends on wall thickness)

The allowable number of cycles is the lesser of:

Half the number of cycles to propagate the crack from initial size to the critical crack depth
The number of cycles to propagate the crack from initial size to the quarter of the critical crack
depth
26

Nf, in air according to the coefficient in KUs research[1]

Coefficients
C = 3.48 x 10-12
m = 3.07

Number of cycles up to critical crack length (a = 0.8t = 7.24 mm)

118,069 cycles

Allowable number of cycles

59,035 cycles (= 0.5 x 118,069)

Design life shall be less than 59,035 cycles

[1] Yamabe et al., Fatigue Life and leak before break assessments of Cr-Mo steel pressure vessels with high pressure gaseous hydrogen, PVP2014-28604

27

Nf, in 28 MPa H2 according to the coefficient in KUs

research[1]
Coefficients
C = 8 x 10-11
m = 3.07
Number of cycles up to critical crack length (a = 0.8t = 7.24 mm)
5,161 cycles
Allowable number of cycles
2,581 cycles (= 0.5 x 5,161)
Design life shall be less than 2,581 cycles
[1] Yamabe et al., Fatigue Life and leak before break assessments of Cr-Mo steel pressure vessels with high pressure gaseous hydrogen, PVP2014-28604

28

Outline
Introduction & aim of the work
Are design codes prepared for the H2-based economy?
Hydrogen-enhanced fatigue according to codes and standards:
Case study
ASME PVP Section VIII Div.2
ASME PVP Section VIII Div. 3 KD-10
EN13445
KHKS 0220
Codes comparison
Conclusions and recommendations

29

Allowable stress to codes

KHK S0220

EN 13445

ASME Sec. VIII Div.2

Material

SCM435 (Cr-Mo steel)

(equivalent KHK
material)

34CrMo4
(equivalent EN 13345
material but with
lower mechanical
properties)

SA372-G.Y.C1.70
(equivalent ASME
material but with
lower mechanical
properties)

Actual cylinder
mechanical
properties

Rp0.2 = 600 MPa

Rm = 780 MPa

Rp0.2 = 600 MPa

Rm = 780 MPa

Rp0.2 = 600 MPa

Rm = 780 MPa

Allowable stress (f)

(MPa)

287.5

325

325

30

Maximum allowable number of cycles according to codes

ASME Sec. VIII
Div.2

ASME Sec. VIII

Div.3 KD10

EN 13445

KHK S 0220

Fatigue analysis
Nf (R=0.07)
Nf (R=0.50)

1,851,566
2.5 (10)11

173,551
1.0 (10)8

255,714

Damage
tolerance
Analysis (FM)
Nf in air (R=0.1)
Nf in H2 (R=0.1)

104,000
4,500

59,035
2,581

31

Maximum allowable number of cycles by fatigue analysis

Fatigue analysis
Nf (R=0.07)
Nf (R=0.70)

ASME Sec. VIII

Div.2

ASME Sec. VIII

Div.3 KD10

EN 13445

KHK S 0220

1,851,566
2.5 E+11

173,551
1.0 E+8

255,714

Seamless component
so kf=1

Surface finish, elasticplastic condition, T,

mean stress effect,
seamless component

Nf
equations:
ff

Fatigue strength
reduction
factors

32

Damage tolerance analysis (Fracture mechanics)

ASME Sec. VIII Div.3 KD10

ASME

KI =

pR 0

R0 Ri

2
3
4

a
a
a
a
2G 0 2G1 + 3G2 4G3 + 5G 4
R
R
R
R

i
i
i

KHK

a
Q

K I = (A0 + A p )G 0 + A1G1 + A2 G 2 + A3G 3

Defect dimensions
ai (initial crack)
a/2C (aspect ratio)

Semi-elliptiical shape
0.500 mm
1/3

LBB criteria
- ac (final)
- remaining
ligament

ac=0.8t
0.2t (KIC/YS)2

da/dN

KHK S 0220

f=C(f(R)Km
f(R)=1

a Q

Semi-elliptiical shape
0.500 mm
1/3

Q = 1 + 4 . 593 (a l )

1 . 65

ac=0.8t
0.2t (KIC/YS)2
f=C(f(R)Km
f(R)=1
33

Outline
Introduction & aim of the work
Are design codes prepared for the H2-based economy?
Hydrogen-enhanced fatigue according to codes and standards:
Case study
ASME PVP Section VIII Div.2
ASME PVP Section VIII Div. 3 KD-10
EN13445
KHKS 0220
Codes comparison
Conclusions and recommendations

34

Fatigue analysis

Conclusions

Differences in codes assessment methods lead to differences on number of allowable

cycles;
No effect of H2 is taken into account in ASME Sec. VIII Div. 2, EN 13445 codes and
KHK S0220 codes;
There is a strong effect of R.

Damage tolerance analysis (Fracture mechanics)

EN13445 and ASME Section VIII Div.2 do not apply fracture mechanics and LBB
assessment;
ASME Sec. VIII Div.3 and KHKS 0220: Same approach is being used by both codes.
However important differences in number of cycles have been found and needs
further explanation.

General comments
Considering the small number of cycles due stable fatigue cracking propagation,
enhanced by hydrogen , it is recommended that materials used for hydrogen
containment in stationary vessels must satisfy the LBB assessment in hydraulic
testing conditions, even if the design code do not recommend it.
In H2 analytical calculations using KIH may not satisfy LBB. However, some
experimental evidences show that LBB is obtained even in high pressure hydrogen
gas [1].
There is still need for proper harmonized determination of KIH.
[1] Yamabe et al., Fatigue Life and leak before break assessments of Cr-Mo steel pressure vessels with high pressure gaseous hydrogen, PVP2014-28604

35

Backup slides

36

API 579 solutions

Reference stress intensity factor solution are given in Annex C of API 579.
2
3
4

a
a
a
a a
2G0 2G1 + 3G2 4G3 + 5G4
KI = 2
2
Q
R0 Ri
Ri
Ri
Ri
Ri
2

pR0

0a/t0.8;
0.03125a/c2;

a is the crack depth

R0, Ri are the outer and inner radius of cylinder, respectively.
G0 = A0,0 + A1,0+ A2,02 + A3,03 + A4,04 + A5,05 + A6,06
G1 = A0,1 + A1,1+ A2,12 + A3,13 + A4,14 + A5,15 + A6,16
=2/
1.65

a
Q = 1 + 1.464
c

for a/c <= 1

1.65

c
Q = 1 + 1.464
a

for a/c > 1

37

API 579 solutions

G2 =
=/2

M1 =

2Q 16 1
16
1

M2 + M3
+ M1 +

15 3
105
12

G3 =

2Q 32 1
32
1

M2 + M3
+ M1 +

35 4
315
20

G4 =

2Q 256 1
256
1

+ M1 +
M2 + M3

315 5
3465
30

2
(3G1 G0 ) 24
5
2Q

M2 = 3

M3 =

6
(G0 2G1 ) + 8
5
2Q

G2 =

Q 4 2
4
1
+ N1 + N2 + N3
5 3
7
2

G3 =

Q 4 1
4
2
+ N1 + N2 + N3
7 2
9
5

G4 =

Q 4 2
4
1
+ N1 + N2 + N3
9 5
11
3

=0

N1 =

3
(2G0 5G1 ) 8
Q

N2 =

15
(3G1 G0 ) + 15
Q

N3 =

3
(3G0 10G1 ) 8
Q
38

API 579 solutions

Reference stress solutions are given
in Annex D of API 579.

LR =

ref
YS

KR =

KI
KMAT

ref

2
2 2
gPb + (gPb ) + 9 Ms Pm (1 )

=
2
3(1 )

0.5

39

Allowable design life, Na, by fatigue analysis in H2 gas

Design life shall be less than 255,714 cycles in air

Little effect of H2 on Nf even in 115 MPa H2 in the long

fatigue life (red band)*
Na is also 255,714 cycles in 28 MPa H2

Note
There are no descriptions for H2 facilities in KHK code,
so the estimation doesnt follow the code

Yamada et al, PVP2014-28511

40

CSA proposal

41

KU proposal

42