ISO/DIS 15869.3

Gaseous hydrogen and hydrogen blends -- Land vehicle fuel tanks

Hydrogène gazeux et mélanges d'hydrogène gazeux -- Réservoirs de carburant pour véhicules terrestres

Standards Content (sample)

DRAFT INTERNATIONAL STANDARD ISO/DIS 15869.3
ISO/TC 197 Secretariat: SCC
Voting begins on: Voting terminates on:
2008-03-26 2008-05-26

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION • МЕЖДУНАРОДНАЯ ОРГАНИЗАЦИЯ ПО СТАНДАРТИЗАЦИИ • ORGANISATION INTERNATIONALE DE NORMALISATION

Gaseous hydrogen and hydrogen blends — Land vehicle fuel
tanks

Hydrogène gazeux et mélanges d'hydrogène gazeux — Réservoirs de carburant pour véhicules terrestres

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.

Member bodies are reminded to consult relevant national interests in each of the technical fields

concerned [Hydrogen technologies (ISO/TC 197), Road vehicles (ISO/TC 22) and Gas cylinder design

(ISO/TC 58/SC 3)] before returning their ballot to the Central Secretariat.

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 publication stage.

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, 2008
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ISO/DIS 15869.3
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ISO/DIS 15869.3
Contents Page

Foreword ...................................................................................................................................................... v

Introduction................................................................................................................................................. vi

1 Scope ............................................................................................................................................... 1

2 Normative references ...................................................................................................................... 1

3 Terms and definitions ..................................................................................................................... 3

4 Service conditions........................................................................................................................... 5

4.1 General............................................................................................................................................. 5

4.2 Expected service ............................................................................................................................. 6

4.3 Working pressure............................................................................................................................ 6

4.4 Maximum filling pressure................................................................................................................ 6

4.5 Filling cycles.................................................................................................................................... 6

4.5.1 General............................................................................................................................................. 6

4.5.2 Reduced number of filling cycles ................................................................................................... 6

4.6 Design temperature......................................................................................................................... 6

4.7 Gas composition ............................................................................................................................. 6

4.8 External surfaces............................................................................................................................. 6

4.9 Fire effects....................................................................................................................................... 7

5 Information to be recorded ............................................................................................................. 7

5.1 General............................................................................................................................................. 7

5.2 Statement of service........................................................................................................................ 7

5.3 Design drawings and information................................................................................................... 7

5.4 Stress analysis report ..................................................................................................................... 8

5.5 Material property data ..................................................................................................................... 8

5.6 Fire protection ................................................................................................................................. 8

5.7 Manufacturing data ......................................................................................................................... 8

6 Materials .......................................................................................................................................... 8

6.1 Compatibility.................................................................................................................................... 8

6.2 Steel ................................................................................................................................................. 9

6.3 Stainless steels ............................................................................................................................... 9

6.4 Aluminium alloys............................................................................................................................. 9

6.5 Resins .............................................................................................................................................. 9

6.6 Fibres ............................................................................................................................................... 9

6.7 Plastic liners .................................................................................................................................... 9

6.8 Metal end bosses............................................................................................................................. 9

7 Design requirements ..................................................................................................................... 10

7.1 General........................................................................................................................................... 10

7.2 Test pressure................................................................................................................................. 10

7.3 Burst pressure and fibre stress ratio............................................................................................ 10

7.3.1 Fuel tank ........................................................................................................................................ 10

7.3.2 Liner ............................................................................................................................................... 11

7.4 Stress analysis .............................................................................................................................. 11

7.5 Maximum defect size..................................................................................................................... 11

7.6 Fire protection ............................................................................................................................... 12

8 Construction and workmanship ................................................................................................... 12

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ISO/DIS 15869.3

8.1 Materials .........................................................................................................................................12

8.2 Type 3 metal liner...........................................................................................................................12

8.3 Neck threads, neck ring, foot ring, attachment for support .........................................................13

8.4 Forming ..........................................................................................................................................13

8.5 Fibre winding..................................................................................................................................13

8.6 Curing of thermosetting resins......................................................................................................13

8.7 Auto-frettage ..................................................................................................................................14

8.8 Exterior environmental protection.................................................................................................14

9 Type (qualification) tests ...............................................................................................................14

9.1 Qualification of new designs .........................................................................................................14

9.2 Generic type tests ..........................................................................................................................15

9.2.1 General ...........................................................................................................................................15

9.2.2 Material tests for steel fuel tanks and liners .................................................................................15

9.2.3 Material tests for aluminium alloy fuel tanks and liners...............................................................15

9.2.4 Material tests for stainless steel liners..........................................................................................16

9.2.5 Material tests for plastic liners ......................................................................................................16

9.2.6 Resin properties tests....................................................................................................................16

9.2.7 Hydrostatic burst pressure test.....................................................................................................16

9.2.8 Ambient temperature pressure cycling test..................................................................................16

9.2.9 Leak-before-break (LBB) test.........................................................................................................16

9.2.10 Bonfire test.....................................................................................................................................17

9.2.11 Penetration test ..............................................................................................................................17

9.2.12 Chemical exposure test .................................................................................................................17

9.2.13 Composite flaw tolerance test .......................................................................................................17

9.2.14 Accelerated stress rupture test .....................................................................................................17

9.2.15 Extreme temperature pressure cycling test..................................................................................17

9.2.16 Impact damage test........................................................................................................................17

9.2.17 Permeation test ..............................................................................................................................17

9.2.18 Boss torque test.............................................................................................................................17

9.2.19 Hydrogen gas cycling test .............................................................................................................17

9.3 Exemptions to generic type tests..................................................................................................18

9.4 Qualification of design changes....................................................................................................18

9.5 Alternative type tests .....................................................................................................................20

10 Production and batch tests............................................................................................................20

10.1 Production tests.............................................................................................................................20

10.2 Batch tests......................................................................................................................................21

10.2.1 General requirements ....................................................................................................................21

10.2.2 Required tests ................................................................................................................................21

10.2.3 Periodic ambient temperature pressure cycling test....................................................................22

10.3 Failure to meet batch and production test requirements .............................................................23

11 Markings .........................................................................................................................................24

12 Preparation for dispatch ................................................................................................................25

Annex A (informative) Rationale for number of filling cycles..................................................................26

Annex B (normative) Test methods and acceptance criteria...................................................................29

Annex C (informative) Verification of stress ratios using strain gauges ................................................38

Annex D (informative) NDE defect size by flawed fuel tank cycling........................................................39

Annex E (normative) Alternative type tests..............................................................................................40

Bibliography................................................................................................................................................43

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ISO/DIS 15869.3
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, ISO/TC 22 Road vehicles

and ISO/TC 58/SC 3 Gas cylinder design.
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ISO/DIS 15869.3
Introduction

Fuel tanks for on-board storage of compressed gaseous hydrogen and hydrogen blends as fuels for land vehicle

service are required to maintain or improve on the level of safety currently existing for land vehicle applications.

These requirements are achieved by:

a) specifying service conditions precisely and comprehensively as a firm basis for both fuel tank design and use;

b) using an appropriate method to assess cyclic pressure fatigue life and to establish allowable defect sizes in

metal tanks or liners;
c) requiring design qualification tests;

d) requiring non-destructive testing and inspection of all production fuel tanks;

e) requiring destructive tests on fuel tanks and tank material taken from each batch of fuel tanks produced;

f) requiring manufacturers to specify the acceptable in-service damage levels for their design; and

g) requiring manufacturers to specify as part of their design, the safe service conditions for their fuel tanks.

Designs meeting the requirements of this International Standard:
a) will have a fatigue life that exceeds the expected service; and

b) will demonstrate appropriate strength and durability for expected service conditions.

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ISO/DIS 15869.3
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 – Metal fuel tanks;
 Type 2 – Hoop wrapped composite fuel tanks with a metal liner;
 Type 3 – Fully wrapped composite fuel tanks with a metal liner;
 Type 4 – Fully wrapped composite fuel tanks with no metal liner.
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

plastics
ISO 2808, Paints and varnishes — Determination of film thickness
ISO 4624, Paints and varnishes — Pull-off test for adhesion
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

testing
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ISO/DIS 15869.3

ISO 9809-1:1999, 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 9809-2:2000, 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 vehicles

ISO/TS 14687-2, Hydrogen fuel — Product specification — Part 2: Proton exchange membrane (PEM) fuel cell

applications for road vehicles

EN 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 litre up to and including 150 litres —

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 cylinders

EN 13322-2:2003/ A1:2006, Transportable gas cylinders — Refillable welded steel gas cylinders — Design and

construction — Part 2: Stainless steel
ASTM 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

Finishes

ASTM D 2344, Standard Test Method for Short-Beam Strength of Polymer Matrix Composite Materials and Their

Laminates

ASTM 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

ASTM D 3418, Standard Test Method for Transition Temperatures and Enthalpies of Fusion and Crystallization of

Polymers by Differential Scanning Calorimetry

ASTM G 154, Standard Practice for Operating Fluorescent Light Apparatus for UV Exposure of Nonmetallic

Materials
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ISO/DIS 15869.3
3 Terms and definitions
3.1
auto-frettage

pressure application procedure used in manufacturing composite fuel tanks with metal liners, which strains the

liner past its yield point

NOTE 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 established
3.3
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 process
3.4
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

3.5
batch 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 process
3.6
burst pressure

pressure that causes the bursting of a pressure vessel subjected to a constant increase of pressure during a

destructive test
3.7
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
3.8
design change

change in the selection of structural materials or dimensional changes exceeding the tolerances as on the design

drawings
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ISO/DIS 15869.3
3.9
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

protection
3.10
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 tank
3.11
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 tank
3.12
hydrogen blend
mixture of natural gas and hydrogen
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 contains hydrogen at the working pressure

3.14
leakage
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 B.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

strength
3.16
manufacturer
organization responsible for the design, manufacturing and testing of fuel tanks
3.17
over-wrap
reinforcement system of filament and resin applied over the liner
3.18
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 pressure
3.18
passenger vehicles

vehicles designed and constructed primarily for the carriage of persons (e.g. cars and buses)

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ISO/DIS 15869.3
3.19
pre-stress
process of applying auto-frettage or controlled tension winding
3.20
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.)

3.21
settled pressure
gas pressure when a given settled temperature is reached
3.22
settled temperature

uniform gas temperature after any change in temperature, caused by filling, has dissipated

3.23
stress ratio

stress in fibre at specified minimum burst pressure divided by stress in fibre at working pressure

3.24
test pressure
required pressure applied during a pressure test
3.25
wor
...