Safety of Gas Storage Systems and Tanks for Dangerous Goods

Division 3.5

The aim of division 3.5 is to make the storage and transport of gases and other dangerous goods safe and efficient. To this end, we research, test and advise on various aspects of gas storage systems and dangerous goods tanks. The term gas storage systems includes all pressurised vessels for gases, but refers in particular to pressure receptacles and gas storage systems for propellants, as well as stationary storage systems if these are used for a gas as an energy carrier - especially hydrogen. Dangerous goods tanks include tank containers, portable tanks, tank vehicles, multiple-element gas containers, bulk containers, mixed loading vehicles, suction-pressure tanks and portable FRP tanks.

The approval in accordance with transparent regulations with possibly worldwide acceptance and the guarantee of safety in operation are the essential preconditions for the trouble-free use of any hazardous goods containment. Ensuring this is a central task of the division in each of its functions, whether as a competent authority, as a notified body for valve components or in market surveillance. Market surveillance relates to applications and containments that are not within the scope for approval of the competent authority. All of this leads to comprehensive contributions to standardisation and reliable, high-quality advice of the federal administration.

We conduct research into the safety and probabilistic risk assessment of containment systems. The focus is on pressure receptacles, gas storage systems in vehicles and gas tanks in the transport of dangerous goods, with an emphasis on new construction methods and materials. In the context of the market ramp-up of hydrogen, the focus is on compressed and cryogenic hydrogen as an energy carrier with regard to safety in production as well as usage and especially in storage. Together with our living lab ‘hydrogen filling station’, these are our contributions to the H2Safety@BAM competence centre.

Fields of expertise

Experience with various safety aspects related to hydrogen
Probabilistic safety analysis with regard to probability of occurrence and risk
Introduction of digital tools into end-to-end process management: From digital application through AI in processing to the digital approval certificate/product passport
Testing of gas storage systems with extensive measurement technology, especially for hydrogen applications
Systematic development of destructive and non-destructive testing methods of containments for dangerous goods
Numerical analysis and simulation methods
Recording and evaluation of gas storage tanks made of composite materials with regard to their ageing, degradation and operational stability
Actively shaping of international regulations on gas storage systems (transport and vehicles)

Main activities

Competent authority and improvement of regulations and standards legal development in for the transport of dangerous goods
Notified body for equipment under the ‘Transportable Pressure Equipment Directive (TPED)’ with test laboratory
Further development of service life monitoring of compressed gas storage systems
Performance of pressure vessel tests
Experimental investigations of storage system behaviour under critical load conditions
Development and testing of modular cryogenic storage tanks
Integration and testing of digital quality assurance tools
International cooperation on hydrogen safety

Range of services/technical equipment

Test benches for hydraulic bursting of pressure vessels with precise pressure control up to over 3000 bar, including extremely low pressure increase rates
Test benches for hydraulic creep conditioning and creep rupture testing at temperatures between RT and +85 °C
Test bench for hydraulic load cycle testing up to 1050 bar at RT and extreme temperatures from -40°C to +85°C
Test benches for drop and impact testing (drop test, high-energy impact test, high-velocity impact test) - also with hydrogen filling
Test stand for fire testing with localized and engulfing fire (e.g. acc. GTR 13#2)
Test rig for determining heat flows through thermal superinsulation, at extreme temperatures in a range of 198°C and +800°C
Various options for mechanical testing of pressure receptacles and gas storage systems
Application of NDT methods to accompany artificial ageing processes or destructive testing
Test rigs for durability testing of equipment parts up to 1500 bar pressure, 200 Nm torque or at extreme temperatures
Test benches for leak testing and flow testing of pressure equipment
Test benches for various mechanical and thermal testing of pressure equipment
Numerical analysis of the effect of approval regulations
Demonstration of operating of digital calibration certificates for measuring devices, etc.
BAM's living lab ‘hydrogen refueling station’ (BAM - News - Digital quality infrastructure for hydrogen: BAM opens unique research refueling station) with extensive opportunities for testing sensors, components, processes and digital tools in quality assurance