Designation: E 2191 – 02

Standard Test Method for

Examination of Gas-Filled Filament-Wound Composite
Pressure Vessels Using Acoustic Emission 1
This standard is issued under the fixed designation E 2191; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (e) indicates an editorial change since the last revision or reapproval.

1. Scope E 650 Guide for Mounting Piezoelectric Acoustic Emission

1.1 This test method provides guidelines for acoustic emis- Sensors2
sion (AE) examination of filament-wound composite pressure E 976 Guide for Determining the Reproducibility of Acous-
vessels, for example, the type used for fuel tanks in vehicles tic Emission Sensor Response2
which use natural gas fuel. E 1316 Terminology for Nondestructive Examinations2
1.2 This test method requires pressurization to a level equal 2.2 Natural Gas Vehicle Standard:
to or greater than what is encountered in normal use. The tanks’ American National Standard for Basic Requirements for
pressurization history must be known in order to use this test Compressed Natural Gas Vehicle (NGV) Fuel
method. Pressurization medium may be gas or liquid. Containers ANSI/AGA/NGV23
1.3 This test method is limited to vessels designed for less 2.3 Compressed Gas Association Standard:
than 10 000 psi (689 bar) maximum allowable working pres- Pamphlet C-6.4, Methods for Visual Inspection of AGA
sure and water volume less than 2.5 ft3(0.07 m3). NGV2 Containers4
1.4 AE measurements are used to detect emission sources. 2.4 U.S. Department of Transportation Reference:
Other nondestructive examination (NDE) methods may be NHTSA Federal Motor Vehicle Safety Standard No. 304,
used to evaluate the significance of AE sources. Procedures for March 27, 19955
other NDE methods are beyond the scope of this test method. 2.5 ASNT Standards:
1.5 This test method applies to examination of new and ANSI/ASNT CP-189, Standard for Qualification and Cer-
in-service filament-wound composite pressure vessels. tification of Nondestructive Testing Personnel6
1.6 This test method applies to examinations conducted at SNT-TC-1A, Recommended Practice for Nondestructive
ambient temperatures above 70°F (21°C). This test method Testing Personnel Qualification and Certification6
may be used at ambient temperatures below 70°F if provision 3. Terminology
has been made to fill to the tank’s rated pressure at 70°F.
1.7 The values stated in inch-pound units are to be regarded 3.1 Definitions—See Terminology E 1316 for general ter-
as the standard. SI units which are in parentheses are for minology applicable to this test method.
information only. 3.2 Definitions of Terms Specific to This Standard:
1.8 This standard does not purport to address all of the 3.2.1 AE test pressure, n—110 % of the greatest pressure
safety concerns, if any, associated with its use. It is the which the test article contains during previous service. Usually
responsibility of the user of this standard to establish appro- 125 % of the filling pressure is an acceptable AE test pressure.
priate safety and health practices and determine the applica- (Normally, gas is heated when compressed during the filling
bility of regulatory limitations prior to use. Specific precau- process; hence, tanks are filled to more than rated service
tionary statements are given in Section 8. pressure). After filling, pressure should settle to rated service
pressure as gas temperature within the tank becomes equal to
2. Referenced Documents ambient temperature.
2.1 ASTM Standards:
E 543 Practice for Agencies Performing Nondestructive
Testing2 3
Available from American National Standards Institute, 25 W. 43rd St., 4th
Floor, New York, NY 10036.
4
Available from Compressed Gas Association, 1725 Jefferson Davis Hwy, Suite
1
This test method is under the jurisdiction of ASTM Committee E07 on 1004, Arlington, VA 22202–4102.
5
Nondestructive Testing and is the direct responsibility of Subcommittee E07.04 on Available from DODSSP, Bldg 4, Section D, 700 Robbins Ave., Philadelphia,
Acoustic Emission Method. PA 19111–5098.
6
Current edition approved March 10, 2002. Published May 2002. Available from American Society for Nondestructive Testing, P.O. Box 28518,
2
Annual Book of ASTM Standards, Vol 03.03. 1711 Arlington Lane, Columbus, OH 43228–0518.

Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.

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 E 2191 – 02
3.2.2 detectability distance, n—the maximum distance from rate (measurable flow noise); mechanical contact with the
a sensor at which a defined simulated AE source can be vessel by objects; electromagnetic interference (EMI) and
detected by the instrumentation with defined settings and using radio frequency interference (RFI) from nearby broadcasting
appropriate pressurization medium. facilities and from other sources; leaks at pipe or hose
connections and airborne particles, insects, rain and snow. This
4. Summary of Test Method test method should not be used if background noise cannot be
4.1 AE sensors are mounted on a vessel and emission is eliminated or controlled.
monitored while the vessel is pressurized to the “AE test
pressure”. 6. Basis of Application
4.2 This test method provides guidelines for the detection of 6.1 Personnel Qualification—NDE personnel shall be
AE from structural flaws in the composite overwrap in gas- qualified in accordance with a nationally recognized practice or
filled, filament-wound composite pressure vessels. Damage standard such as ANSI/ASNT-CP-189, SNT-TC-1A, or a
mechanisms which produce AE include: resin cracking, fiber similar document. The practice or standard used and its
debonding, fiber pullout, fiber breakage, delamination and applicable revisions shall be specified in any contractual
bond failure. Flaws in liner portions of a vessel may not be agreement between the using parties.
detected. 6.2 Qualification of Nondestructive Test Agencies—If speci-
4.3 This test method and others found in ASTM, ASME, fied in the contractual agreement, NDT agencies shall be
ASNT, SPI relate Acoustic Emission to applied load on the qualified and evaluated as described in Practice E 543. The
composite material. At relatively low load (safe operating applicable edition of Practice E 543 shall be specified in the
conditions) the acoustic emission from the composite material contractual agreement.
is low. At higher loads (unsafe operating conditions) the slope 6.3 Extent of Examination—The extent of examination shall
of the AE versus load curve changes drastically. In some cases be in accordance with 4.2 unless otherwise specified.
this phenomenon can be identified and quantified by a single 6.4 Reporting Criteria/Acceptance Criteria—Reporting cri-
AE parameter (that is, AE counts). teria for the examination results shall be in accordance with
4.4 Structurally insignificant flaws or processes (for ex- Section 11 unless otherwise specified. Acceptance criteria shall
ample, leaks) may produce emission. be specified in the contractual agreement.
4.5 This test method is convenient for periodic examination 6.5 Personnel Training/Test Requirements—NDE personnel
of vessels in-service. (examiner) shall be familiar with CGA Pamphlet C6 and shall
4.6 Gas-filled filament-wound pressure vessels which ex- have attended a training course and passed a written test which
hibit unacceptable levels of AE should be examined by other cover the following topics.
methods; for example, visual, ultrasound, dye penetrant, etc., 6.5.1 Basic technology of acoustic emission.
and may be repaired and re-examined in accordance with
6.5.2 Failure mechanisms of reinforced plastics.
government regulations and manufacturers guidelines. Repair
6.5.3 Acoustic emission instrumentation.
and repair examination procedures are outside the scope of this
6.5.4 Instrumentation check out.
test method.
6.5.5 Vessel filling requirements.
4.7 Any number of pressure vessels may be examined
6.5.6 Data collection and interpretation.
simultaneously as long as the appropriate number of sensors
6.5.7 Test report.
and instrumentation channels are used.
5. Significance and Use 7. Apparatus
5.1 Due to safety considerations, the Compressed Gas 7.1 Essential features of the apparatus required for this
Association (CGA) and others have produced guidelines which standard are shown in Fig. 1. Specifications are provided in
address in-service inspection of NGV fuel containers (see Annex A1.
2.2-2.4). AE examination is listed as an alternative to the 7.2 Couplant must be used to acoustically couple sensors to
minimum three-year visual examination which generally re- the vessel surface. Adhesives that have acceptable acoustic
quires that the container be removed from the vehicle to expose properties and traditional couplants are acceptable.
the entire container surface. The AE method allows “in-situ” 7.3 Sensors may be held in place with elastic straps,
examination of the container. adhesive tape, or other mechanical means.
5.1.1 Slow-fill pressurization must proceed at flow rates that 7.4 On small vessels (that is, where 100 % coverage can be
do not produce background noise from flow of the pressurizing achieved with two sensors) the sensor locations on the vessel
medium. Acoustic emission data are recorded throughout a wall will be determined by accessibility. Ideally they should be
pressurization range (that is, 50 % to 100 % of AE test placed 180° apart at opposite ends of the container on the
pressure). shoulders.
5.1.2 Fast-fill pressurization can be used if hold periods are 7.5 On larger vessels (that is, where two sensors cannot
provided. Acoustic emission data are recorded only during the provide 100 % coverage) sensors are positioned on the vessel
hold periods. wall so as to provide complete coverage. Sensor spacings are
5.1.3 Background noise above the threshold will contami- governed by the attenuation of the material. If attenuation
nate the AE data and render them useless. Users must be aware characteristics are not available from previous examinations of
of the following common causes of background noise: high fill similar vessels follow the directions found below.

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 E 2191 – 02

FIG. 1 Essential Features of the Apparatus

7.5.1 Attenuation Characterization—Typical signal propa- 7.8 Power/signal cable length (that is, cable between pream-
gation losses shall be determined in accordance with the plifier and signal processor) shall not result in a signal loss of
following procedure. This procedure provides a relative mea- greater than 3 dB [typically 500 ft (150 m) is acceptable].
sure of the attenuation but may not be representative of a 7.9 Signal processors are computerized instruments with
genuine AE source. It should be noted that peak amplitude independent channels that filter, measure and convert analog
caused by a mechanical pencil lead break may vary with information into digital form for display and permanent stor-
surface hardness, resin condition and cure. Select a represen- age. A signal processor must have sufficient speed and capacity
tative region of the vessel with clear access along the cylin- to independently process data from all sensors simultaneously.
drical section. Mount an AE sensor and mark off 6-in. intervals The signal processor should provide capability to filter data for
from the center of the sensor along a line parallel to the replay.
principal direction of the surface fiber. Select additional points 7.10 A video monitor is used to display processed data in
on the surface of the vessel at 6-in. (15-cm) intervals along various formats. Display format may be selected by the
lines angled 45° and 90°, respectively, to the principal direction examiner.
of the surface fiber. Break pencil leads (see Guide E 976) and 7.11 A data storage device, such as a magnetic disk, is used
record peak amplitude. All lead breaks shall be done at an to store data for replay or for archives.
angle of approximately 30° to the surface with a 0.1 in. (2.5 7.12 Hard-copy capability should be available from a
mm) lead extension. The attenuation data shall be retained as graphics/line printer or equivalent device.
part of the test report.
7.5.2 Record the distances from the center of the sensor to 8. Safety Precautions
the points where hits are no longer detected. Repeat this 8.1 Ambient temperature should not be below the ductile-
procedure along lines angled 45° and 90° to the direction of the brittle transition temperature of the pressure vessel liner.
original line. The data shall be retained as part of the test
report. The minimum distance from the sensor at which the 9. Calibration and Standardization
pencil lead break can no longer be detected is known as the 9.1 Annual calibration and verification of pressure trans-
detectability distance; this distance shall be recorded. ducer (if applicable), AE sensors, preamplifiers (if applicable),
7.5.3 Sensor spacing (distance between adjacent sensors) signal processor (particularly the signal processor time refer-
shall not be greater than 1.5 times the detectability distance. ence), and AE electronic waveform generator should be per-
7.6 AE sensors are used to detect stress waves produced by formed. Equipment should be adjusted so that it conforms to
flaws. Sensors must be held in contact with the vessel wall to equipment manufacturer’s specifications. Instruments used for
ensure adequate acoustic coupling. calibrations must have current accuracy certification that is
7.7 A preamplifier may be enclosed in the sensor housing or traceable to the National Institute for Standards and Technol-
in a separate enclosure. If a separate preamplifier is used, cable ogy (NIST).
length, between sensor and preamplifier, must not result in a 9.2 Routine electronic evaluations must be performed on a
signal loss of greater than 3 dB [typically 6 ft (1.8 m) is monthly basis or at any time there is concern about signal
acceptable]. processor performance. An AE electronic waveform generator

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 E 2191 – 02
should be used in making evaluations. Each signal processor 10.8 Monitor test by observing displays that show plots of
channel must respond with peak amplitude reading within 62 AE activity versus time or pressure. If unusual response is
dB of the electronic waveform generator output. observed, interrupt pressurization and conduct an investigation
9.3 Routine performance checking of each sensor should be to determine the cause.
conducted on a monthly basis or at any time there is concern 10.9 Store all data on mass storage media. Stop test when
about the sensor performance. Peak amplitude response and pressure reaches AE test pressure.
electronic noise level should be recorded. Sensors can be 10.10 Compare the data to acceptance criteria and record
stimulated by a pencil lead break or electronic waveform results (see Appendix X1).
generator with a pulser. Sensors which are found to have peak 10.11 Vessels which have produced excessive emission may
amplitudes or electronic noise more than 3 dB greater or less be re-examined immediately.
than the average of the group of sensors to be used during the 10.12 Carry out the system performance check at each
examination should be replaced. sensor (see 9.4). Verify that peak amplitude is greater than a
9.4 A system performance check must be conducted imme- specified value (see Table X1.1).
diately before and immediately after each examination. A
11. Report
performance check uses a mechanical device to induce stress
waves into the vessel wall at a specified distance from each 11.1 Prepare a written report for each examination. Reports
sensor. The induced stress waves simulate emission from a should contain the following information:
flaw. Performance checks verify performance of each system 11.1.1 Name of owner of vessel and vehicle number (if
channel including couplant). appropriate).
9.4.1 The preferred technique for conducting a performance 11.1.2 Examination date and location.
check is a pencil lead break. Lead should be broken on the 11.1.3 Previous examination date and previous maximum
vessel surface at a specified distance from the sensor (see test pressure. See Note 2.
Figure 4 of Guide E 976). NOTE 2—If the examiner is aware of situations where the vessel was
9.4.2 System channels which are found to have performance subject to pressures that exceeded normal fill pressure or incidents during
outside of specified values should be repaired or replaced. handling or collisions involving a vehicle in which the test article was
mounted, these should be described in the report.

10. Test Procedure 11.1.4 Record all information printed on the vessel.
11.1.5 Any DOT exemption numbers that apply to the
10.1 Visually examine accessible exterior surfaces of the vessel.
vessel. Note observations in the test report (see CGA Pamphlet 11.1.6 Normal fill pressure and marked service pressure.
C-6.4). 11.1.7 Pressurization medium.
10.2 Visually examine the tank exterior surface and remove 11.1.8 Pressure at which data acquisition commenced.
any objects which come into contact. When vessel cannot be 11.1.9 Maximum test pressure.
completely isolated, record in the test report external sources 11.1.10 Attenuation data (see 7.5.1).
which could have produced emission. 11.1.11 Signature of examiner.
10.3 Connect fill hose (and pressure transducer if used). 11.1.12 Sketch which shows relative locations of vessels (if
Eliminate any leaks at connections. multiple vessels are being examined) and which shows sensor
10.4 Mount acoustic emission sensors. Use procedures locations.
specified in Section 7 and in Guide E 650. 11.1.13 Pre-examination and post-examination system per-
10.5 Adjust signal processor (see Table X1.1). formance check results.
10.6 Perform system performance check at each sensor. 11.1.14 Visual examination results.
Verify that peak amplitude is greater than a specified value (see 11.1.15 AE examination results.
Table X1.1). Details relating to a mechanical device that is
used to produce stress waves are found in 9.4 and in Table 12. Precision and Bias
X1.1. Prior to pressurization, verify that there is no background 12.1 Sensitivity is influenced by factors that affect elastic
noise above the signal processor threshold setting (see Table wave propagation, sensor coupling and signal processor set-
X1.1). tings.
12.2 It is possible to measure AE from AE sources that
NOTE 1—If desired sensitivity cannot be attained with sensors at two
locations, more sensors must be used to provide complete coverage (see
cannot be verified by other NDE methods.
7.4 and 7.5). 13. Keywords
10.7 Begin pressurizing vessel. Fast-fill or slow-fill pressure 13.1 acoustic emission; composite pressure vessel; cylin-
schedule may be used (see Annex A2 and Annex A3). ders; flaws; gas pressure; NGV tanks

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 E 2191 – 02
ANNEXES

(Mandatory Information)

A1. INSTRUMENTATION SPECIFICATIONS

A1.1 Sensors A1.4.3 Preamplifier shall be shielded from electromagnetic

A1.1.1 AE broadband or resonant sensors shall have high interference.
sensitivity somewhere within the 20 to 1200 kHz frequency A1.4.4 Preamplifiers of differential design shall have a
band. minimum of 40 dB common mode rejection.
A1.1.2 Peak sensitivity shall be greater than -77 dB (re- A1.4.5 Preamplifier shall include a bandpass filter with a
ferred to 1V/µbar, determined by face-to-face ultrasonic minimum of 24 dB/octave signal attenuation above and below
method) in the frequency range of 20 to 1200 kHz. frequency band which is used.
A1.1.3 Sensor sensitivity shall not vary more than 3 dB over
A1.5 Power/Signal Cable
the intended range of temperatures in which sensors are used.
A1.1.4 Sensors shall be shielded against electromagnetic A1.5.1 Power/signal cables provide power to preamplifiers
interference through proper design practice or differential and conduct amplified signals to the main processor. These
(anti-coincidence) element design, or both. shall be shielded against electromagnetic interference. Signal
A1.1.5 Sensors shall be electrically isolated from conduc- loss shall be less than 3 dB [typically 500 ft (150 m)]. Standard
tive surfaces by means of a shoe (a wear plate). coaxial cable is generally adequate.

A1.6 Power Supply

A1.2 Signal Cable
A1.6.1 A stable, grounded, power supply that meets signal-
A1.2.1 The sensor signal cable which connects sensor and
processor manufacturer’s specification shall be used.
preamplifier shall not be longer than what will result in a 3 dB
signal loss [typically 6 ft (1.8 m)]. Integral preamplifier sensors A1.7 Signal Processor
meet this requirement. They have inherently short, internal,
signal cables. A1.7.1 Electronic circuitry gain shall be stable within 62
A1.2.2 Signal cable shall be shielded against electromag- dB in the temperature range 40 to 100°F (4.4 to 37.8°C).
netic interference. Standard coaxial cable is generally ad- A1.7.2 Threshold shall be accurate with 62 dB.
equate. A1.7.3 Measured AE parameters may include: threshold
crossing counts, peak amplitude, relative energy, hit duration,
risetime and arrival time for each hit. Also, vessel internal
A1.3 Couplant
pressure shall be measured.
A1.3.1 Couplant shall provide adequate acoustic coupling A1.7.4 The counter circuit shall count threshold crossing
throughout the examination. within an accuracy of 65 % of true counts.
A1.3.2 Couplant must be temperature stable over the tem- A1.7.5 Peak amplitude shall be accurate within 62 dB.
perature range intended for use. A1.7.6 Relative energy shall be accurate within 610 energy
A1.3.3 Adhesives may be used if they satisfy acoustic counts.
coupling and temperature stability requirements. A1.7.7 Duration shall be accurate to within 610 µs.
A1.7.8 Risetime shall be accurate to within 610 µs.
A1.4 Preamplifier A1.7.9 Arrival time at each channel shall be accurate to
A1.4.1 Preamplifier shall have noise level no greater than 7 within 61.0 µs.
µV rms (referred to a shorted input) within the bandpass range. A1.7.10 Parametric voltage readings from pressure trans-
A1.4.2 Preamplifier gain shall vary no more than 61 dB ducers (if used) shall be accurate to within 65 % of AE test
within the frequency band and temperature range of use. pressure.

A2. FAST-FILL PRESSURIZATION SCHEDULE

A2.1 Fast-fill pressurization rates [in excess of 200 psi/min determine a baseline of the background noise. This data
(14 bar/min)] may produce flow noise which can overload AE provides an estimate of the total background noise contribution
instrumentation. during the examination. Background noise shall be discounted
in the final data analysis.
A2.2 Hold periods in the pressurization schedule are not
subject to flow noise and are used exclusively to collect data.
A2.4 Intermediate load holds (b,c,d of Fig. A2.1) shall be
The vessel must be monitored continuously during hold
periods. for 2 min.

A2.3 The initial hold period (a of Fig. A2.1) is used to A2.5 The final hold (e of Fig. A2.1) shall be for 10 min.

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 E 2191 – 02

FIG. A2.1

A3. SLOW-FILL PRESSURIZATION SCHEDULE

A3.1 Slow-fill pressurization rates produce little or no flow in the final data analysis.
noise.
A3.3 Intermediate hold periods are unnecessary and data
A3.2 The initial hold period (a of Fig. A3.1) is used to can be collected continuously during pressurization (b of Fig.
determine a baseline of the background noise. This data A3.1).
provides an estimate of the total background noise contribution
during the examination. Background noise shall be discounted A3.4 The final hold (c of Fig. A3.1) shall be for 10 min.

FIG. A3.1

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 E 2191 – 02

APPENDIX

(Nonmandatory Information)

X1. EXAMPLE INSTRUMENT SETTINGS AND ACCEPTANCE CRITERIA BASED ON COUNTS

X1.1 A data base and acceptance criteria based on counts X1.6.3 If more than 50 000 counts are recorded, re-examine
has been established for NGV2-2 fuel tanks.7 immediately. If the repeat test produces 50 000 AE counts or
more, remove the vessel from service.
X1.2 Test pressure is 110 % of the pressure which a tank
sees during service. (Usually 110 % of the normal fill pres- X1.7 Acceptance criteria are the same for both fast fill and
sure.) slow fill.
X1.3 Pressure in the container must remain below 1000 psi X1.8 Acoustic emission equipment, characteristics and
(69 bar) for minimum of 8 h immediately prior to the set-up conditions are found in Table X1.1.
examination.
X1.9 NDT personnel should be qualified in accordance
X1.4 Emission can originate from flaws which are any- with ANSI/ASNT-CP-189.
where on the cylindrical section or ends of the vessel.
TABLE X1.1 Acoustic Emission Equipment, Characteristics and
X1.5 Acceptance criteria are based on “AE counts” as Set-Up Conditions
defined in Terminology E 1316. Sensor Resonance 150 kHz 6 50 kHz
Sensor Sensitivity -77 dB ref. 1V/µbar at 150 kHz
X1.6 Acceptance Criteria: Sensor Placement On composite overwrap
Couplant Silicone grease or hot-melt glue
X1.6.1 If less than 10 000 threshold crossing counts are Preamplifier Gain 40 dB (3100) (nominal)
recorded, no action required. Preamplifier Filter 100 to 200 kHz bandpass minimum
X1.6.2 If 10 000 to 50 000 counts are recorded, immedi- Power/Signal Cable Length < 500 ft (150 m)
Signal Processor Threshold 40 dB (0 dB = 1 µV at the preamplifier input
ately repeat the AE test. If the repeat test does not produce less Signal Processor Filter 100 to 300 kHz bandpass
than 10 000 AE counts, perform an examination 1 year hence. Dead Time 1 ms
Hit Definition Time 400 µs
Hit Lockout Time > 200 µs
Background Noise < 27 dB (0 dB = 1 µV at the preamplifier input)
7
Fultineer, Jr. R.D. and Mitchell, J.R., Field Data on Testing of NGV Containers System Performance Check > 70 dB (0 dB = 1 µV at the preamplifier input)
Using Proposed ASTM Standard Test Method for Examination of Gas-Filled Using Lead Break
Filament-Wound Pressure Vessels Using Acoustic Emission (ASTM E070403-95/1, (0.3 mm, 2H, >4 in. from sensor)
Acoustic Emission: Standards and Technology Update, ASTM STP 1353, S.J. see Guide E 976
Vahaviolos, Editor, American Society for Testing and Materials, 1998.

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