ISO/DIS 15869.4
(Main)Gaseous hydrogen and hydrogen blends -- Land vehicle fuel tanks
Gaseous hydrogen and hydrogen blends -- Land vehicle fuel tanks
Hydrogène gazeux et mélanges d'hydrogène gazeux -- Réservoirs de carburant pour véhicules terrestres
General Information
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Standards Content (sample)
DRAFT INTERNATIONAL STANDARD ISO/DIS 15869
ISO/TC 197 Secretariat: SCC
Voting begins on Voting terminates on
2011-07-07 2011-12-07
INTERNATIONAL ORGANIZATION FOR STANDARDIZATION • МЕЖДУНАРОДНАЯ ОРГАНИЗАЦИЯ ПО СТАНДАРТИЗАЦИИ • ORGANISATION INTERNATIONALE DE NORMALISATION
Gaseous hydrogen and hydrogen blends — Land vehicle fueltanks
Hydrogène gazeux et mélanges d'hydrogène gazeux — Réservoirs de carburant pour véhicules terrestres
(Revision of ISO/TS 15869:2009)ICS 43.060.40
In accordance with the provisions of Council Resolution 15/1993 this document is circulated in
the English language only.Conformément aux dispositions de la Résolution du Conseil 15/1993, ce document est
distribué en version anglaise seulement.To expedite distribution, this document is circulated as received from the committee
secretariat. ISO Central Secretariat work of editing and text composition will be undertaken at
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secrétariat du comité. Le travail de rédaction et de composition de texte sera effectué au
Secrétariat central de l'ISO au stade de publication.THIS DOCUMENT IS A DRAFT CIRCULATED FOR COMMENT AND APPROVAL. IT IS THEREFORE SUBJECT TO CHANGE AND MAY NOT BE
REFERRED TO AS AN INTERNATIONAL STANDARD UNTIL PUBLISHED AS SUCH.IN ADDITION TO THEIR EVALUATION AS BEING ACCEPTABLE FOR INDUSTRIAL, TECHNOLOGICAL, COMMERCIAL AND USER PURPOSES, DRAFT
INTERNATIONAL STANDARDS MAY ON OCCASION HAVE TO BE CONSIDERED IN THE LIGHT OF THEIR POTENTIAL TO BECOME STANDARDS TO
WHICH REFERENCE MAY BE MADE IN NATIONAL REGULATIONS.RECIPIENTS OF THIS DRAFT ARE INVITED TO SUBMIT, WITH THEIR COMMENTS, NOTIFICATION OF ANY RELEVANT PATENT RIGHTS OF WHICH
THEY ARE AWARE AND TO PROVIDE SUPPORTING DOCUMENTATION.© International Organization for Standardization, 2011
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ISO/DIS 15869
Copyright notice
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ii © ISO 2011 – All rights reserved
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ISO/DIS 15869
Contents Page
Foreword ............................................................................................................................................................. v
1 Scope ...................................................................................................................................................... 1
2 Normative references ............................................................................................................................ 1
3 Terms and definitions ........................................................................................................................... 3
4 Categories of fuel tanks ........................................................................................................................ 5
4.1 Type of fuel ............................................................................................................................................ 5
4.2 Nominal working pressure ................................................................................................................... 6
4.3 Type of service ...................................................................................................................................... 6
4.4 Designation ............................................................................................................................................ 6
5 Service conditions ................................................................................................................................. 6
5.1 General ................................................................................................................................................... 6
5.2 Maximum filling pressure ..................................................................................................................... 7
5.3 Filling cycles .......................................................................................................................................... 7
5.4 Design temperature ............................................................................................................................... 7
5.5 Gas composition ................................................................................................................................... 7
5.6 External surfaces ................................................................................................................................... 7
5.7 Fire effects ............................................................................................................................................. 7
6 Information to be recorded ................................................................................................................... 7
6.1 General ................................................................................................................................................... 7
6.2 Statement of service ............................................................................................................................. 7
6.3 Design drawings and information ....................................................................................................... 8
6.4 Stress analysis report ........................................................................................................................... 8
6.5 Material property data ........................................................................................................................... 8
6.6 Fire protection ....................................................................................................................................... 9
6.7 Manufacturing data ............................................................................................................................... 9
7 Materials ................................................................................................................................................. 9
7.1 Compatibility .......................................................................................................................................... 9
7.2 Steel ........................................................................................................................................................ 9
7.3 Stainless steels ...................................................................................................................................... 9
7.4 Aluminium alloys ................................................................................................................................... 9
7.5 Resins ..................................................................................................................................................... 9
7.6 Fibres .................................................................................................................................................... 10
7.7 Plastic liners ........................................................................................................................................ 10
7.8 Metal end bosses ................................................................................................................................. 10
8 Design requirements ........................................................................................................................... 10
8.1 General ................................................................................................................................................. 10
8.2 Test pressure ....................................................................................................................................... 10
8.3 Burst pressure and fibre stress ratio ................................................................................................ 10
8.3.1 Fuel tank ............................................................................................................................................... 10
8.3.2 Liner ...................................................................................................................................................... 11
8.4 Stress analysis .................................................................................................................................... 11
8.5 Maximum defect size ........................................................................................................................... 12
8.6 Fire protection ..................................................................................................................................... 12
9 Construction and workmanship ........................................................................................................ 12
9.1 Materials ............................................................................................................................................... 12
9.2 Type 3 metal liner ................................................................................................................................ 13
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ISO/DIS 15869
9.3 Neck threads, neck ring, foot ring, attachment for support ........................................................... 13
9.4 Forming ................................................................................................................................................ 13
9.5 Fibre winding ....................................................................................................................................... 13
9.6 Curing of thermosetting resins ......................................................................................................... 14
9.7 Auto-frettage ....................................................................................................................................... 14
9.8 Exterior environmental protection .................................................................................................... 14
10 Qualification of new designs ............................................................................................................. 15
10.1 General ................................................................................................................................................. 15
10.2 Material tests ....................................................................................................................................... 15
10.2.1 General ................................................................................................................................................. 15
10.2.2 Material tests for steel fuel tanks and liners .................................................................................... 15
10.2.3 Material tests for aluminium alloy fuel tanks and liners ................................................................. 15
10.2.4 Material tests for stainless steel liners ............................................................................................. 16
10.2.5 Material tests for plastic liners .......................................................................................................... 16
10.2.6 Resin properties tests ........................................................................................................................ 16
10.3 Baseline tests ...................................................................................................................................... 16
10.3.1 General ................................................................................................................................................. 16
10.3.2 Hydrostatic burst pressure test ........................................................................................................ 17
10.3.3 Ambient temperature pressure cycling test .................................................................................... 17
10.3.4 Leak-before-break (LBB) test ............................................................................................................ 17
10.3.5 Fire test ................................................................................................................................................ 17
10.3.6 High strain rate impact test ............................................................................................................... 17
10.3.7 Boss torque test.................................................................................................................................. 17
10.4 Type tests ............................................................................................................................................ 17
10.4.1 General ................................................................................................................................................. 17
10.4.2 Chemical exposure test ..................................................................................................................... 18
10.4.3 Composite flaw tolerance test ........................................................................................................... 18
10.4.4 Accelerated stress rupture test ......................................................................................................... 18
10.4.5 Extreme temperature pressure cycling test ..................................................................................... 18
10.4.6 Impact damage test ............................................................................................................................ 18
10.4.7 Permeation test ................................................................................................................................... 18
10.4.8 Hydrogen gas cycling test ................................................................................................................. 18
10.5 Exemptions .......................................................................................................................................... 18
10.6 Qualification of design changes ....................................................................................................... 19
11 Production and batch tests ............................................................................................................... 21
11.1 Production tests.................................................................................................................................. 21
11.2 Batch tests ........................................................................................................................................... 21
11.2.1 General requirements ......................................................................................................................... 21
11.2.2 Required tests ..................................................................................................................................... 22
11.2.3 Periodic ambient temperature pressure cycling test ...................................................................... 23
11.3 Failure to meet batch and production test requirements ............................................................... 23
12 Markings .............................................................................................................................................. 24
13 Preparation for dispatch .................................................................................................................... 25
Annex A (normative) Requirements for hydrogen blends service ............................................................. 26
Annex B (informative) Rationale for number of filling cycles, permeation rates and carbon fibre
stress ratio considerations ................................................................................................................ 27
Annex C (informative) Manufacturer’s instructions for handling, use and inspection of tanks .............. 31
Annex D (informative) Verification of stress ratios using strain gauges ................................................... 33
Annex E (informative) NDE defect size by flawed fuel tank cycling ........................................................... 34
Annex F (normative) Test methods and acceptance criteria ....................................................................... 35
Annex G (normative) Alternative testing method for fuel tanks of service type A ................................... 44
Bibliography ..................................................................................................................................................... 48
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ISO/DIS 15869
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies
(ISO member bodies). The work of preparing International Standards is normally carried out through ISO
technical committees. Each member body interested in a subject for which a technical committee has been
established has the right to be represented on that committee. International organizations, governmental and
non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely with the
International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization.
International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2.
The main task of technical committees is to prepare International Standards. Draft International Standards
adopted by the technical committees are circulated to the member bodies for voting. Publication as an
International Standard requires approval by at least 75 % of the member bodies casting a vote.
Attention is drawn to the possibility that some of the elements of this document may be the subject of patent
rights. ISO shall not be held responsible for identifying any or all such patent rights.
ISO 15869 was prepared by Technical Committee ISO/TC 197, Hydrogen technologies with collaboration from
Technical Committee ISO/TC 22, Road vehicles, and Technical Committee ISO/TC 58, Gas cylinders,
Subcommittee SC 3, Cylinder design.This edition cancels and replaces ISO/TS 15869:2009, which has been technically revised.
© ISO 2011 – All rights reserved v---------------------- Page: 5 ----------------------
DRAFT INTERNATIONAL STANDARD ISO/DIS 15869
Gaseous hydrogen and hydrogen blends — Land vehicle fuel
tanks
1 Scope
This International Standard specifies the requirements for lightweight refillable fuel tanks intended for the on-board
storage of high-pressure compressed gaseous hydrogen or hydrogen blends on land vehicles .
This International Standard is not intended as a specification for fuel tanks used for solid, liquid hydrogen or hybrid
cryogenic-high pressure hydrogen storage applications.This International Standard is applicable for fuel tanks of steel, stainless steel, aluminium or non-metallic
construction material, using any design or method of manufacture suitable for its specified service conditions.
This Standard applies to the following types of fuel tank designs: Type 1 – all - metal fuel tank;
Type 2 – hoop wrapped fuel tank with a load sharing metal liner and composite reinforcement on the
cylindrical part only; Type 3 – fully wrapped fuel tank with a load sharing metal liner and composite reinforcement on both the
cylindrical part and dome ends; Type 4 – fully wrapped fuel tank with a non-load sharing liner and composite reinforcement in both the
cylindrical part and dome ends.2 Normative references
The following referenced documents are indispensable for the application of this document. For dated references,
only the edition cited applies. For undated references, the latest edition of the referenced document (including any
amendments) applies.ISO 306, Plastics — Thermoplastic materials — Determination of Vicat softening temperature (VST)
ISO 527-2, Plastics — Determination of tensile properties — Part 2: Test conditions for moulding and extrusion
plasticsISO 2808, Paints and varnishes — Determination of film thickness
ISO 4624, Paints and varnishes — Pull-off test for adhesion
The first edition of this International Standard only covers gaseous hydrogen and hydrogen blends fuel tanks for use onboard
light duty four-wheel passenger road vehicles and heavy-duty road vehicles. Fuel tanks for other applications are to be added
in the next editions.© ISO 2011 – All rights reserved 1
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ISO/DIS 15869
ISO 6506-1, Metallic materials — Brinell hardness test — Part 1: Test method
ISO 7225, Gas cylinders — Precautionary labels
ISO 7866:1999, Gas cylinders — Refillable seamless aluminium alloy gas cylinders — Design, construction and
testingISO 9809-1:2010, Gas cylinders — Refillable seamless steel gas cylinders — Design, construction and testing —
Part 1: Quenched and tempered steel cylinders with tensile strength less than 1 100 MPa
ISO 9809-2:2010, Gas cylinders — Refillable seamless steel gas cylinders — Design, construction and testing —
Part 2: Quenched and tempered steel cylinders with tensile strength greater than or equal to 1 100 MPa
ISO 11114-4, Transportable gas cylinders — Compatibility of cylinder and valve materials with gas contents —
Part 4: Test methods for selecting metallic materials resistant to hydrogen embrittlement
ISO 11439, Gas cylinders — High pressure cylinders for the on-board storage of natural gas as a fuel for
automotive vehiclesISO 14687-1, Hydrogen fuel — Product specification —Part 1: All applications except proton exchange membrane
(PEM) fuel cells for road vehiclesISO 14687-2 Hydrogen fuel — Product specification — Part 2: Proton exchange membrane (PEM) fuel cell
applications for road vehiclesEN 1964-3:2000, Transportable gas cylinders — Specification for the design and construction of refillable
transportable seamless steel gas cylinders of water capacities from 0,5 l up to and including 150 l — Part 3:
Cylinders made of seamless stainless steel with an Rm value of less than 1100 MPa
EN 12862:2000, Transportable gas cylinders — Specification for the design and construction of refillable
transportable welded aluminium alloy gas cylindersEN 13322-2:2003, Transportable gas cylinders — Refillable welded steel gas cylinders — Design and
construction — Part 2: Stainless steelCSA HPRD-1: 2007, Basic Requirements for Pressure Relief Devices for Compressed Hydrogen Vehicle Fuel
ContainersASTM B 117, Standard Practice for Operating Salt Spray (Fog) Apparatus
ASTM D 522, Standard Test Methods for Mandrel Bend Test of Attached Organic Coatings
ASTM D 1308, Standard Test Method for Effect of Household Chemicals on Clear and Pigmented Organic
FinishesASTM D 2344, Standard Test Method for Short-Beam Strength of Polymer Matrix Composite Materials and Their
LaminatesASTM D 2794, Standard Test Method for Resistance of Organic Coatings to the Effects of Rapid Deformation
(Impact)ASTM D 3170, Standard Test Method for Chipping Resistance of Coatings
1) To be published.
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ISO/DIS 15869
ASTM D 3418, Standard Test Method for Transition Temperatures of Polymers by Differential Scanning
CalorimetryASTM G 154, Standard Practice for Operating Fluorescent Light Apparatus for UV Exposure of Nonmetallic
Materials3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
3.1
auto-frettage
pressure application procedure used in manufacturing composite fuel tanks with metal liners, which strains the
liner past its yield pointNOTE Auto-frettage results in the liner having compressive stresses and the fibres having tensile stresses at zero internal
pressure.3.2
auto-frettage pressure
pressure within the over-wrapped composite fuel tank at which the required distribution of stresses between the
liner and the over-wrap is established3.3
batch of composite fuel tanks
group of not more than 200 fuel tanks plus fuel tanks for destructive testing, or if greater, one shift of successive
production of fuel tanks, successively produced from qualified liners having the same size, design, specified
materials of construction and manufacturing process3.4
batch of metal fuel tanks/liners
group of not more than 200 fuel tanks/liners plus fuel tanks/liners for destructive testing, or if greater, one shift of
successive production of metal fuel tanks/liners, successively produced having the same nominal diameter, wall
thickness, design, specified material of construction, manufacturing process, equipment for manufacturing and
heat treatment, and conditions of time, temperature and atmosphere during heat treatment
3.5batch of non-metallic liners
group of not more than 200 liners plus liners for destructive testing, or if greater, one shift of successive
production of non-metallic liners, successively produced having the same nominal diameter, wall thickness,
design, specified material of construction and manufacturing process3.6
burst pressure
pressure that causes the bursting of a pressure vessel subjected to a constant increase of pressure during a
destructive test3.7
controlled tension winding
process used in manufacturing hoop-wrapped composite fuel tanks with metal liners by which compressive
stresses in the liner and tensile stresses in the over-wrap at zero internal pressure are obtained by winding the
reinforcing filaments under high tension© ISO 2011 – All rights reserved 3
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ISO/DIS 15869
3.8
design change
change in the selection of structural materials or dimensional changes exceeding the tolerances as on the design
drawings3.9
finished fuel tanks
fuel tanks, which are ready for, use, typical of normal production, complete with identification marks and external
coating including integral insulation specified by the manufacturer, but free from non-integral insulation or
protection3.10
fully wrapped composite fuel tank
fuel tank with an over-wrap having a filament wound reinforcement both in the circumferential and axial direction
of the fuel tank3.11
hoop-wrapped composite fuel tank
fuel tank with an over-wrap having a filament wound reinforcement in a substantially circumferential pattern over
the cylindrical portion of the liner so that the filament does not carry any significant load in a direction parallel to
the longitudinal axis of the fuel tank3.12
hydrogen blend
mixture of natural gas and more than 2% hydrogen by volume
3.13
hydrogen storage system
system on a land vehicle comprised of the fuel tank and all closure devices (e.g. shut-off valves, check valves and
thermally activated pressure relief devices) and piping that contain hydrogen at the nominal working pressure
3.14leakage
release of gas through a crack, pore, unbonded or similar defect
NOTE Permeation through the wall of a Type 4 fuel tank that is less than the rates described in F.16 is not considered
leakage.3.15
liner
container that is used as an inner shell, on which reinforcing fibres are filament wound to reach the necessary
strength3.16
manufacturer
organization responsible for the design, manufacturing and testing of fuel tanks
3.17
nominal working pressure
settled pressure of compressed gas at a uniform temperature of 15 °C in a full fuel tank
3.18over-wrap
reinforcement system of filament and resin applied over the liner
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ISO/DIS 15869
3.19
thermally activated pressure relief device
device that activates by temperature to release pressure and prevent a fuel tank from bursting due to fire effects
and which will activate regardless of fuel tank pressure3.20
pre-stress
process of applying auto-frettage or controlled tension winding
3.21
service conditions
conditions that the fuel tank will experience in service and which includes on-road exposure to environmental
factors (road salt, acids, bases, temperature extremes) and expected usage (pressure cycles associated with
filling and defilling during service and driving, static pressure associated with vehicle parking, etc.)
3.22settled pressure
gas pressure when a given set
...
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