ANNEX 1

ESSENTIAL CHARACTERISTICS OF THE VEHICLE, ENGINE AND LPG-RELATED EQUIPMENT

ANNEX 2A

ARRANGEMENT OF THE LPG EQUIPMENT TYPE-APPROVAL MARK

(See paragraph 5.2. of this Regulation)

a ≥ 5 mm

The above approval mark affixed to the LPG equipment shows that this equipment has been approved in the Netherlands (E4), pursuant to Regulation No 67 under approval number 012439. The first two digits of the approval number indicate that the approval was granted in accordance with the requirements of Regulation No 67 as amended by the 01 series of amendments (1).

(1)  Class 1, 2, 2A or 3

ANNEX 2B

COMMUNICATION

ANNEX 2C

ARRANGEMENT OF APPROVAL MARKS

MODEL A

(See paragraph 16.2. of this Regulation)

a ≥ 8 mm

The above approval mark affixed to a vehicle shows that the vehicle has, with regard to the installation of specific equipment for the use of LPG for propulsion, been approved in the Netherlands (E4), pursuant to Regulation No 67 under approval number 012439. The first two digits of the approval number indicate that the approval was granted in accordance with the requirements of Regulation No 67 as amended by the 01 series of amendments.

MODEL B

(See paragraph 16.2. of this Regulation)

a ≥ 8 mm

The above approval mark affixed to a vehicle shows that the vehicle has, with regard to the installation of specific equipment for the use of LPG for propulsion, been approved in the Netherlands (E4), pursuant to Regulation No 67 under approval number 012439. The first two digits of the approval number indicate that the approval was granted in accordance with the requirements of Regulation No 67 as amended by the 01 series of amendments and that Regulation No 83 included the 04 series of amendments.

ANNEX 2D

COMMUNICATION

ANNEX 3

PROVISIONS REGARDING THE APPROVAL OF LPG CONTAINER ACCESSORIES

80 per cent stop valve

1.1.   Definition: see paragraph 2.5.1. of this Regulation.

1.2.   Component classification (according to Figure 1, para. 2.): Class 3.

1.3.   Classification pressure: 3 000 kPa.

1.4.   Design temperatures:

–20 °C to 65 °C

For temperatures exceeding the above-mentioned values, special tests conditions are applicable.

1.5.   General design rules:

Paragraph 6.15.1., Provisions regarding 80 per cent stop valve.

Paragraph 6.15.2., Provisions regarding the electrical insulation.

Paragraph 6.15.3.1., Provisions on valves activated by electrical power.

1.6.   Applicable test procedures:

Level indicator

2.1.   Definition: see paragraph 2.5.2. of this Regulation.

2.2.   Component classification (according to Figure 1, para. 2.): Class 1.

2.3.   Classification pressure: 3 000 kPa.

2.4.   Design temperatures:

–20 °C to 65 °C

For temperatures exceeding the above-mentioned values, special tests conditions are applicable.

2.5.   General design rules:

Paragraph 6.15.11., Provisions regarding the level indicator.

Paragraph 6.15.2., Provisions regarding the electrical insulation.

2.6.   Applicable test procedures:

Pressure relief valve (discharge valve)

3.1.   Definition: see paragraph 2.5.3. of this Regulation.

3.2.   Component classification (according to Figure 1, para. 2.): Class 3.

3.3.   Classification pressure: 3 000 kPa.

3.4.   Design temperatures:

–20 °C to 65 °C

For temperatures exceeding the above-mentioned values, special tests conditions are applicable.

3.5.   General design rules:

Paragraph 6.15.8., Provisions regarding the pressure relief valve (discharge valve)

3.6.   Applicable test procedures:

Remotely controlled service valve with excess flow valve

4.1.   Definition: see paragraph 2.5.4. of this Regulation.

4.2.   Component classification (according to Figure 1, para. 2.): Class 3.

4.3.   Classification pressure: 3 000 kPa.

4.4.   Design temperatures:

–20 °C to 65 °C

For temperatures exceeding the above-mentioned values, special tests conditions are applicable.

4.5.   General design rules:

Paragraph 6.15.2., Provisions regarding the electrical insulation.

Paragraph 6.15.3.1., Provisions on valves activated by an electrical/external power.

Paragraph 6.15.13., Provisions regarding the remotely controlled service valve with excess flow valve.

4.6.   Applicable test procedures:

Power supply bushing

5.1.   Definition: see paragraph 2.5.8. of this Regulation.

5.2.   Component classification (according to Figure 1, para. 2.): Class 1.

5.3.   Classification pressure: 3 000 kPa.

5.4.   Design temperatures:

–20 °C to 65 °C

For temperatures exceeding the above-mentioned values, special tests conditions are applicable.

5.5.   General design rules:

Paragraph 6.15.2., Provisions regarding the electrical insulation.

Paragraph 6.15.2.3., Provisions regarding the power supply bushing.

5.6.   Applicable test procedures:

Gas-tight housing

6.1.   Definition: See paragraph 2.5.7. of this Regulation.

6.2.   Component classification (according to Figure 1, para. 2.):

Not applicable.

6.3.   Classification pressure: Not applicable.

6.4.   Design temperatures:

–20 °C to 65 °C

For temperatures exceeding the above-mentioned values, special tests conditions are applicable.

6.5.   General design rules:

Paragraph 6.15.12., Provisions regarding the gas-tight housing.

6.6.   Applicable test procedures:

Provisions regarding the approval of the pressure relief device (fuse)

7.1.   Definition: see paragraph 2.5.3.1. of this Regulation.

7.2.   Component classification (according to Figure 1, paragraph 2.): Class 3.

7.3.   Classification pressure: 3 000 kPa.

7.4.   Design temperature:

The fuse has to be designed to open at a temperature of 120 ± 10 °C

7.5.   General design rules

Paragraph 6.15.2., Provisions regarding the electrical insulation

Paragraph 6.15.3.1., Provisions on valves activated by electrical power

Paragraph 6.15.7., Provisions regarding the gas tube pressure relief valve

7.6.   Test procedures to be applied:

7.7.   Pressure relief device (fuse) requirements

Pressure relief device (fuse) specified by the manufacturer shall be shown to be compatible with the service conditions by means of the following tests:

(*1)  Only for non-metallic parts.

(*2)  Only for metallic parts.

(*3)  This procedure, or other equivalent, is allowed until an international standard will be available.

ANNEX 4

PROVISIONS REGARDING THE APPROVAL OF THE FUEL PUMP

1.   Definition: see paragraph 2.5.5. of this Regulation.

2.   Component classification (according to Figure 1, para. 2.): Class 1.

3.   Classification pressure: 3 000 kPa.

4.   Design temperatures:

–20 °C to 65 °C, when the fuel pump is mounted inside the container.

–20 °C to 120 °C, when the fuel pump is mounted outside the container.

For temperatures exceeding the above-mentioned values, special tests conditions are applicable.

5.   General design rules:

Paragraph 6.15.2., Provisions regarding the electrical insulation.

Paragraph 6.15.2.1., Provisions regarding the insulation class.

Paragraph 6.15.3.2., Provisions when the power is switched off.

Paragraph 6.15.6.1., Provisions to prevent pressure build-up.

Applicable test procedures:

6.1.   Fuel pump mounted inside the container:

6.2.   Fuel pump mounted outside the container:

(*1)  Only for non-metallic parts.

(*2)  Only for metallic parts.

ANNEX 5

PROVISIONS REGARDING THE APPROVAL OF THE LPG FILTER UNIT

1.   Definition: see paragraph 2.14. of this Regulation.

2.   Component classification (according to Figure 1, para. 2.):

Filter units can be Class 1, 2 or 2A.

3.   Classification pressure:

4.   Design temperatures:

–20 °C to 120 °C

For temperatures exceeding the above-mentioned values, special tests conditions are applicable.

5.   General design rules: (not used)

Applicable test procedures:

6.1.   For parts of Class 1:

6.2.   For parts of Class 2 and/or 2A:

(*1)  Only for non-metallic parts.

(*2)  Only for metallic parts.

ANNEX 6

PROVISIONS REGARDING THE APPROVAL OF THE PRESSURE REGULATOR AND THE VAPORIZER

1.   Definition:

2.   Component classification (according to Figure 1, para. 2.):

3.   Classification pressure:

4.   Design temperatures:

–20 °C to 120 °C

For temperatures exceeding the above-mentioned values, special tests conditions are applicable.

5.   General design rules:

Paragraph 6.15.2., Provisions regarding the electrical insulation.

Paragraph 6.15.3.1., Provisions on valves activated by external power.

Paragraph 6.15.4., Heat exchange medium (compatibility and pressure requirements).

Paragraph 6.15.5., Overpressure bypass security.

Paragraph 6.15.6.2., Gas flow prevention.

Applicable test procedures:

6.1.   For parts of Class 1:

6.2.   For parts of Class 2 and/or 2A:

Remarks:

The shut-off valve can be integrated in the vaporizer, regulator, in this case Annex 7 is also applicable.

The parts of the pressure regulator/vaporizer (Class 1, 2 or 2A) shall be leakproof with the outlet(s) of that part closed off.

For the overpressure test all the outlets including those of the coolant compartment shall be closed off.

(*1)  Only for non-metallic parts.

(*2)  Only for metallic parts.

ANNEX 7

PROVISIONS REGARDING THE APPROVAL OF THE SHUT-OFF VALVE, THE NON-RETURN VALVE, THE GAS-TUBE PRESSURE RELIEF VALVE AND THE SERVICE COUPLING

Provisions regarding the approval of the shut-off valve

1.1.   Definition: see paragraph 2.8. of this Regulation.

1.2.   Component classification (according to Figure 1, para. 2.): Class 3.

1.3.   Classification pressure: 3 000 kPa.

1.4.   Design temperatures:

–20 °C to 120 °C

For temperatures exceeding the above-mentioned values, special tests conditions are applicable.

1.5.   General design rules:

Paragraph 6.15.2., Provisions regarding the electrical insulation.

Paragraph 6.15.3.1., Provisions on valves activated by electrical power.

1.6.   Applicable test procedures:

Provisions regarding the approval of the non-return valve

2.1.   Definition: see paragraph 2.5.9. of this Regulation.

2.2.   Component classification (according to Figure 1, para. 2.): Class 1.

2.3.   Classification pressure: 3 000 kPa.

2.4.   Design temperatures:

–20 °C to 120 °C

For temperatures exceeding the above-mentioned values, special tests conditions are applicable.

2.5.   General design rules:

Paragraph 6.15.2., Provisions regarding the electrical insulation.

Paragraph 6.15.3.1., Provisions on valves activated by electrical power.

2.6.   Applicable test procedures:

Provisions regarding the approval of the gas-tube relief valve

3.1.   Definition: see paragraph 2.9. of this Regulation.

3.2.   Component classification (according to Figure 1, para. 2.): Class 3.

3.3.   Classification pressure: 3 000 kPa.

3.4.   Design temperatures:

–20 °C to 120 °C

For temperatures exceeding the above-mentioned values, special tests conditions are applicable.

3.5.   General design rules:

Paragraph 6.15.2., Provisions regarding the electrical insulation.

Paragraph 6.15.3.1., Provisions on valves activated by electrical power.

Paragraph 6.15.7., Provisions regarding the gas-tube pressure relief valve.

3.6.   Applicable test procedures:

Provisions regarding the approval of the service coupling

4.1.   Definition: see paragraph 2.17. of this Regulation.

4.2.   Component classification (according to Figure 1, para. 2.): Class 1.

4.3.   Classification pressure: 3 000 kPa.

4.4.   Design temperatures:

–20 °C to 120 °C

For temperatures exceeding the above-mentioned values, special tests conditions are applicable.

4.5.   General design rules:

Paragraph 6.15.2., Provisions regarding the electrical insulation.

Paragraph 6.15.3.1., Provisions on valves activated by electrical power.

4.6.   Applicable test procedures:

(*1)  Only for non-metallic parts.

(*2)  Only for metallic parts.

ANNEX 8

PROVISIONS REGARDING THE APPROVAL OF FLEXIBLE HOSES WITH COUPLINGS

SCOPE

The purpose of this annex is to determine the provisions regarding the approval of flexible hoses for use with LPG, having an inside diameter up to 20 mm.

This annex covers three types of flexible hoses:

1.   HIGH PRESSURE RUBBER HOSES, CLASS 1 CLASSIFICATION, FILLING HOSE

1.1.   General specifications

1.1.1.   The hose shall be so designed as to withstand a maximum operating pressure of 3 000 kPa.

1.1.2.   The hose shall be so designed as to withstand temperatures between –25 °C and +80 °C. For operating temperatures exceeding the above- mentioned values, the test temperatures must be adapted.

1.1.3.   The inside diameter shall be in compliance with Table 1 of standard ISO 1307.

1.2.   Hose construction

1.2.1.   The hose must embody a smooth-bore tube and a cover of suitable synthetic material, reinforced with one or more interlayer(s).

1.2.2.   The reinforcing interlayer(s) has (have) to be protected by a cover against corrosion.

If for the reinforcing interlayer(s) corrosion-resistant-material is used (i.e. stainless-steel) a cover is not required.

1.2.3.   The lining and the cover must be smooth and free from pores, holes and strange elements.

An intentionally provided puncture in the cover shall not be considered as an imperfection.

1.2.4.   The cover has to be intentionally perforated to avoid the forming of bubbles.

1.2.5.   When the cover is punctured and the interlayer is made of a non-corrosion-resistant material, the interlayer has to be protected against corrosion.

1.3.   Specifications and tests for the lining

Tensile strength and elongation

1.3.1.1.    Tensile strength and elongation at break according to ISO 37. Tensile strength not less than 10 MPa and elongation at break not less than 250 per cent.

1.3.1.2.    Resistance to n-pentane according to ISO 1817 with the following conditions:

Requirements:

After storage in air with a temperature of 40 °C for a period of 48 hours the mass compared to the original value may not decrease more than 5 per cent.

1.3.1.3.    Resistance to ageing according to ISO 188 with the following conditions:

Requirements:

1.4.   Specifications and test-method for the cover

Tensile strength and elongation at break according to ISO 37. Tensile strength not less than 10 MPa and elongation at break not less than 250 per cent.

1.4.1.1.    Resistance to n-hexane according to ISO 1817 with the following conditions:

Requirements:

1.4.1.2.    Resistance to ageing according to ISO 188 with the following conditions:

Requirements:

Resistance to ozone

1.4.2.1.   The test has to be performed in compliance with standard ISO 1431/1.

1.4.2.2.   The test-pieces, which have to be stretched to an elongation of 20 per cent shall have to be exposed to air of 40 °C with an ozone-concentration of 50 parts per hundred million during 120 hours.

1.4.2.3.   No cracking of the test pieces is allowed.

1.5.   Specifications for uncoupled hose

Gas-tightness (permeability)

1.5.1.1.   A hose at a free length of 1 m has to be connected to a container filled with liquid propane, having a temperature of 23 ± 2 °C.

1.5.1.2.   The test has to be carried out in compliance with the method described in standard ISO 4080.

1.5.1.3.   The leakage through the wall of the hose shall not exceed 95 cm3 of vapour per metre of hose per 24 h.

Resistance at low temperature

1.5.2.1.   The test has to be carried out in compliance with the method described in standard ISO 4672:1978 method B.

1.5.2.2.   Test-temperature: –25 ± 3 °C.

1.5.2.3.   No cracking or rupture is allowed.

1.5.3.   (Not used)

Bending test

1.5.4.1.   An empty hose, at a length of approximately 3,5 m must be able to withstand 3 000 times the hereafter prescribed alternating-bending-test without breaking. After the test the hose must be capable of withstanding the test-pressure as mentioned in paragraph 1.5.5.2.

Figure 1

(example only)

mass

propulsion mechanism

1.5.4.3.   The testing machine (see Figure 1) shall consist of a steel frame, provided with two wooden wheels, with a rim-width of c.a. 130 mm.

The circumference of the wheels must be grooved for the guidance of the hose. The radius of the wheels, measured to the bottom of the groove, must be as indicated in paragraph 1.5.4.2.

The longitudinal median planes of both wheels must be in the same vertical plane and the distance between the wheel-centres must be in accordance with paragraph 1.5.4.2.

Each wheel must be able to rotate freely round its pivot-centre.

A propulsion mechanism pulls the hose over the wheels at a speed of four complete motions per minute.

1.5.4.4.   The hose shall be S-shape-like installed over the wheels (see Figure 1).

The end, that runs over the upper wheel shall be furnished with a sufficient mass as to achieve a complete snuggling of the hose against the wheels. The part that runs over the lower wheel is attached to the propulsion mechanism.

The mechanism must be so adjusted, that the hose travels a total distance of 1,2 m in both directions.

Hydraulic test pressure and determination of the minimum burst-pressure

1.5.5.1.   The test has to be carried out in compliance with the method described in standard ISO 1402.

1.5.5.2.   The test-pressure of 6 750 kPa shall be applied during 10 minutes, without any leakage.

1.5.5.3.   The burst pressure shall not be less than 10 000 kPa.

1.6.   Couplings

1.6.1.   The couplings shall be made from steel or brass and the surface must be corrosion-resistant.

The couplings must be of the crimp-fitting type.

1.6.2.1.   The swivel-nut must be provided with U.N.F. thread.

1.6.2.2.   The sealing cone of swivel-nut type must be of the type with a half vertical angle of 45°.

1.6.2.3.   The couplings can be made as swivel-nut type or as quick-connector type.

1.6.2.4.   It shall be impossible to disconnect the quick-connector type without specific measures or the use of dedicated tools.

1.7.   Assembly of hose and couplings

1.7.1.   The construction of the couplings must be such, that it is not necessary to peel the cover unless the reinforcement of the hose consists of corrosion-resistant material.

The hose assembly has to be subjected to an impulse test in compliance with standard ISO 1436.

1.7.2.1.   The test has to be completed with circulating oil having a temperature of 93 °C, and a minimum pressure of 3 000 kPa.

1.7.2.2.   The hose has to be subjected to 150 000 impulses.

1.7.2.3.   After the impulse test the hose has to withstand the test-pressure as mentioned in paragraph 1.5.5.2.

Gas-tightness

1.7.3.1.   The hose assembly (hose with couplings) has to withstand during five minutes a gas pressure of 3 000 kPa without any leakage.

1.8.   Markings

Every hose must bear, at intervals of not greater than 0,5 m, the following clearly legible and indelible identification markings consisting of characters, figures or symbols.

1.8.1.1.   The trade name or mark of the manufacturer.

1.8.1.2.   The year and month of fabrication.

1.8.1.3.   The size and type-marking.

1.8.1.4.   The identification marking ‘L.P.G. Class 1’.

1.8.2.   Every coupling shall bear the trade name or mark of the assembling manufacturer.

2.   LOW PRESSURE RUBBER HOSES, CLASS 2 CLASSIFICATION

2.1.   General specifications

2.1.1.   The hose shall be so designed as to withstand a maximum operating pressure of 450 kPa.

2.1.2.   The hose shall be so designed as to withstand temperatures between –25 °C and + 125 °C. For operating temperatures exceeding the above- mentioned values, the test temperatures must be adapted.

2.2.   Hose construction

2.2.1.   The hose must embody a smooth-bore tube and a cover of suitable synthetic material, reinforced with one or more interlayer(s).

2.2.2.   The reinforcing interlayer(s) has (have) to be protected by a cover against corrosion.

If for the reinforcing interlayer(s) corrosion-resistant material is used (i.e. stainless steel) a cover is not required.

2.2.3.   The lining and the cover must be smooth and free from pores, holes and strange elements.

An intentionally provided puncture in the cover shall not be considered as an imperfection.

2.3.   Specifications and tests for the lining

Tensile strength and elongation

2.3.1.1.   Tensile strength and elongation at break according to ISO 37. Tensile strength not less than 10 MPa and elongation at break not less than 250 per cent.

2.3.1.2.   Resistance to n-pentane according to ISO 1817 with the following conditions:

Requirements:

After storage in air with a temperature of 40 °C for a period of 48 hours the mass compared to the original value may not decrease more than 5 per cent.

2.3.1.3.   Resistance to ageing according to ISO 188 with the following conditions:

Requirements:

2.4.   Specifications and test method for the cover

2.4.1.1.   Tensile strength and elongation at break according to ISO 37. Tensile strength not less than 10 MPa and elongation at break not less than 250 per cent.

2.4.1.2.   Resistance to n-hexane according to ISO 1817 with the following conditions:

Requirements:

2.4.1.3.   Resistance to ageing according to ISO 188 with the following conditions:

Requirements:

Resistance to ozone

2.4.2.1.   The test has to be performed in compliance with standard ISO 1431/1.

2.4.2.2.   The test-pieces, which have to be stretched to an elongation of 20 per cent shall have to be exposed to air of 40 °C with an ozone concentration of 50 parts per hundred million during 120 hours.

2.4.2.3.   No cracking of the test pieces is allowed.

2.5.   Specifications for uncoupled hose

Gas-tightness (permeability)

2.5.1.1.   A hose at a free length of 1 m has to be connected to a container filled with liquid propane, having a temperature of 23 ± 2 °C.

2.5.1.2.   The test has to be carried out in compliance with the method described in standard ISO 4080.

2.5.1.3.   The leakage through the wall of the hose shall not exceed 95 cm3 of vapour per metre of hose per 24 h.

Resistance at low temperature

2.5.2.1.   The test has to be carried out in compliance with the method described in standard ISO 4672-1978 method B.

2.5.2.2.   Test-temperature: –25 ± 3 °C

2.5.2.3.   No cracking or rupture is allowed.

Bending test

2.5.3.1.   An empty hose, at a length of approximately 3,5 m must be able to withstand 3 000 times the hereafter prescribed alternating-bending-test without breaking. After the test the hose must be capable of withstanding the test pressure as mentioned in paragraph 2.5.4.2.

Figure 2

(example only)

mass

propulsion mechanism

2.5.3.3.   The testing machine (see Figure 2) shall consist of a steel frame, provided with two wooden wheels, with a rim-width of c.a. 130 mm.

The circumference of the wheels must be grooved for the guidance of the hose. The radius of the wheels, measured to the bottom of the groove, must be as indicated in paragraph 2.5.3.2.

The longitudinal median planes of both wheels must be in the same vertical plane and the distance between the wheel-centres must be in accordance with paragraph 2.5.3.2.

Each wheel must be able to rotate freely round its pivot-centre.

A propulsion mechanism pulls the hose over the wheels at a speed of four complete motions per minute.

2.5.3.4.   The hose shall be S-shape-like installed over the wheels (see Figure 2).

The end that runs over the upper wheel shall be furnished with a sufficient mass as to achieve a complete snuggling of the hose against the wheels. The part that runs over the lower wheel is attached to the propulsion mechanism.

The mechanism must be so adjusted, that the hose travels a total distance of 1,2 m in both directions.

Hydraulic test pressure and determination of the minimum burst-pressure

2.5.4.1.   The test has to be carried out in compliance with the method described in standard ISO 1402.

2.5.4.2.   The test pressure of 1 015 kPa shall be applied during 10 minutes, without any leakage.

2.5.4.3.   The burst pressure shall not be less than 1 800 kPa.

2.6.   Couplings

2.6.1.   The couplings shall be made from a non-corrosive material.

2.6.2.   The coupling burst pressure in mounted position shall never be less than the tube or hose burst pressure.

The coupling leakage pressure in mounted position shall never be less than the tube or hose leakage pressure.

2.6.3.   The couplings must be of the crimp-fitting type.

2.6.4.   The couplings can be made as swivel-nut type or as quick-connector type.

2.6.5.   It shall be impossible to disconnect the quick-connector type without specific measures or the use of dedicated tools.

2.7.   Assembly of hose and couplings

2.7.1.   The construction of the couplings must be such, that it is not necessary to peel the cover unless the reinforcement of the hose consists of corrosion-resistant material.

The hose assembly has to be subjected to an impulse test in compliance with standard ISO 1436.

2.7.2.1.   The test has to be completed with circulating oil having a temperature of 93 °C, and a minimum pressure of 1 015 kPa.

2.7.2.2.   The hose has to be subjected to 150 000 impulses.

2.7.2.3.   After the impulse test the hose has to withstand the test-pressure as mentioned in paragraph 2.5.4.2.

Gas-tightness

2.7.3.1.   The hose assembly (hose with couplings) has to withstand during five minutes a gas pressure of 1 015 kPa without any leakage.

2.8.   Markings

Every hose must bear, at intervals of not greater than 0,5 m, the following clearly legible and indelible identification markings consisting of characters, figures or symbols.

2.8.1.1.   The trade name or mark of the manufacturer.

2.8.1.2.   The year and month of fabrication.

2.8.1.3.   The size and type-marking.

2.8.1.4.   The identification marking ‘L.P.G. Class 2’.

2.8.2.   Every coupling shall bear the trade name or mark of the assembling manufacturer.

3.   HIGH PRESSURE SYNTHETIC HOSES, CLASS 1 CLASSIFICATION

3.1.   General specifications

3.1.1.   The purpose of this chapter is to determine the provisions regarding the approval of synthetic flexible hoses for use with LPG, having an inside diameter up to 10 mm.

3.1.2.   This chapter covers, in addition to general specifications and tests for synthetic hoses, also specifications and tests applicable for specific material types or a synthetic hose.

3.1.3.   The hose shall be so designed as to withstand a maximum operating pressure of 3 000 kPa.

3.1.4.   The hose shall be so designed as to withstand temperatures between –25 °C and + 125 °C. For operating temperatures exceeding the above-mentioned values, the test temperatures must be adapted.

3.1.5.   The inside diameter shall be in compliance with Table 1 of standard ISO 1307.

3.2.   Hose construction

3.2.1.   The synthetic hose must embody a thermoplastic tube and a cover of suitable thermoplastic material, oil and weatherproof, reinforced with one or more synthetic interlayer(s). If for the reinforcing interlayer(s) a corrosion-resistant material is used (i.e. stainless-steel) a cover is not required.

3.2.2.   The lining and the cover must be free from pores, holes and strange elements.

An intentionally provided puncture in the cover shall not be considered as an imperfection.

3.3.   Specifications and tests for the lining

Tensile strength and elongation

3.3.1.1.    Tensile strength and elongation at break according to ISO 37. Tensile strength not less than 20 MPa and elongation at break not less than 200 per cent.

3.3.1.2.    Resistance to n-pentane according to ISO 1817 with the following conditions:

Requirements:

After storage in air with a temperature of 40 °C for a period of 48 hours the mass compared to the original value may not decrease more than 5 per cent.

3.3.1.3.    Resistance to ageing according to ISO 188 with the following conditions:

Requirements:

Tensile strength and elongation specific for polyamide 6 material

3.3.2.1.    Tensile strength and elongation at break according to ISO 527-2 with the following conditions:

The material has to be conditioned for at least 21 days at 23 °C and 50 per cent relative humidity prior to testing.

Requirements:

3.3.2.2.    Resistance to n-pentane according to ISO 1817 with the following conditions:

Requirements:

After storage in air with a temperature of 40 °C for a period of 48 hours the mass compared to the original value may not decrease more than 5 per cent.

3.3.2.3.    Resistance to ageing according to ISO 188 with the following conditions:

After ageing the specimens have to be conditioned at 23 °C and 50 per cent relative humidity for at least 21 days prior to carrying out the tensile test according to paragraph 3.3.2.1.

Requirements:

3.4.   Specifications and test method for the cover

3.4.1.1.    Tensile strength and elongation at break according to ISO 37. Tensile strength not less than 20 MPa and elongation at break not less than 250 per cent.

3.4.1.2.    Resistance to n-hexane according to ISO 1817 with the following conditions:

Requirements:

3.4.1.3.    Resistance to ageing according to ISO 188 with the following conditions:

Requirements:

Resistance to ozone

3.4.2.1.   The test has to be performed in compliance with standard ISO 1431/1.

3.4.2.2.   The test-pieces, which have to be stretched to an elongation of 20 per cent shall have to be exposed to air of 40 °C and a relative humidity of 50 per cent ±10 per cent with an ozone-concentration of 50 parts per hundred million during 120 hours.

3.4.2.3.   No cracking of the test pieces is allowed.

Specifications and test method for the cover made of polyamide 6 material

3.4.3.1.    Tensile strength and elongation at break according to ISO 527-2 with the following conditions:

The material has to be conditioned for at least 21 days at 23 °C and 50 per cent relative humidity prior to testing.

Requirements:

3.4.3.2.    Resistance to n-hexane according to ISO 1817 with the following conditions:

Requirements:

3.4.3.3.    Resistance to ageing according to ISO 188 with the following conditions:

After ageing the specimens have to be conditioned for at least 21 days before carrying out the tensile test according to paragraph 3.3.1.1.

Requirements:

3.5.   Specifications for uncoupled hose

Gas-tightness (permeability)

3.5.1.1.   A hose at a free length of 1 m has to be connected to a container filled with liquid propane, having a temperature of 23 ± 2 °C.

3.5.1.2.   The test has to be carried out in compliance with the method described in standard ISO 4080.

3.5.1.3.   The leakage through the wall of the hose shall not exceed 95 cm3 of vapour per metre of hose per 24 h.

Resistance at low temperature

3.5.2.1.   The test has to be carried out in compliance with the method described in standard ISO 4672 method B.

3.5.2.2.   Test temperature: –25 ± 3 °C.

3.5.2.3.   No cracking or rupture is allowed.

Resistance at high temperature

3.5.3.1.   A piece of hose, pressurized at 3 000 kPa, with a minimal length of 0,5 m must be put in an oven at a temperature of 125 ± 2 °C during 24 hours.

3.5.3.2.   No leakage is allowed.

3.5.3.3.   After the test the hose shall withstand the test pressure of 6 750 kPa during 10 minutes. No leakage is allowed.

Bending test

An empty hose, at a length of approximately 3,5 m must be able to withstand 3 000 times the hereafter prescribed alternating-bending-test without breaking. After the test the hose must be capable of withstanding the test pressure as mentioned in paragraph 3.5.5.2.

Figure 3

(example only) (a = 102 mm; b = 241 mm)

mass

propulsion mechanism

3.5.4.2.   The testing machine (see Figure 3) shall consist of a steel frame, provided with two wooden wheels, with a rim-width of approximately 130 mm.

The circumference of the wheels must be grooved for the guidance of the hose. The radius of the wheels, measured to the bottom of the groove, must be 102 mm.

The longitudinal median planes of both wheels must be in the same vertical plane. The distance between the wheel-centres must be vertical 241 mm and horizontal 102 mm.

Each wheel must be able to rotate freely round its pivot-centre.

A propulsion mechanism pulls the hose over the wheels at a speed of four complete motions per minute.

3.5.4.3.   The hose shall be S-shape-like installed over the wheels (see Figure 3).

The end, that runs over the upper wheel, shall be furnished with a sufficient mass as to achieve a complete snuggling of the hose against the wheels. The part that runs over the lower wheel is attached to the propulsion mechanism.

The mechanism must be so adjusted, that the hose travels a total distance of 1,2 m in both directions.

Hydraulic test pressure and determination of the minimum burst-pressure

3.5.5.1.   The test has to be carried out in compliance with the method described in standard ISO 1402.

3.5.5.2.   The test pressure of 6 750 kPa shall be applied during 10 minutes, without any leakage.

3.5.5.3.   The burst pressure shall not be less than 10 000 kPa.

3.6.   Couplings

3.6.1.   The couplings shall be made from steel or brass and the surface must be corrosion-resistant.

3.6.2.   The couplings must be of the crimp-fitting type and made up of a hose-coupling or banjo bolt. The sealing shall be resistant to LPG and comply with paragraph 3.3.1.2.

3.6.3.   The banjo bolt shall comply with DIN 7643.

3.7.   Assembly of hose and couplings

The hose assembly has to be subjected to an impulse test in compliance with standard ISO 1436.

3.7.1.1.   The test has to be completed with circulating oil having a temperature of 93 °C, and a minimum pressure of 3 000 kPa.

3.7.1.2.   The hose has to be subjected to 150 000 impulses.

3.7.1.3.   After the impulse-test the hose has to withstand the test pressure as mentioned in paragraph 3.5.5.2.

Gas-tightness

3.7.2.1.   The hose assembly (hose with couplings) has to withstand during five minutes a gas pressure of 3 000 kPa without any leakage.

3.8.   Markings

Every hose must bear, at intervals of not greater than 0,5 m, the following clearly legible and indelible identification markings consisting of characters, figures or symbols.

3.8.1.1.   The trade name or mark of the manufacturer.

3.8.1.2.   The year and month of fabrication.

3.8.1.3.   The size and type-marking.

3.8.1.4.   The identification marking ‘L.P.G. Class 1’.

3.8.2.   Every coupling shall bear the trade name or mark of the assembling manufacturer.

ANNEX 9

PROVISIONS REGARDING THE APPROVAL OF THE FILLING UNIT

1.   Definition: see paragraph 2.16. of this Regulation.

2.   Component classification (according to Figure 1, para. 2.):

Filling unit: Class 3

Non-return valve: Class 3

3.   Classification pressure: 3 000 kPa.

4.   Design temperatures:

–20 °C to 65 °C

For temperatures exceeding the above-mentioned values, special tests conditions are applicable.

5.   General design rules:

Paragraph 6.15.2., Provisions regarding the electrical insulation.

Paragraph 6.15.10., Provisions regarding the filling unit.

6.   Applicable test procedures:

Impact test requirements for the Euro filling unit

7.1.   General requirements

The filling unit shall be subjected to an impact test of 10 J.

7.2.   Test procedure

A hardened steel mass of 1 kg shall be dropped from a height of 1 m so as to deliver the impact velocity 4,4 m/s. This shall be achieved by mounting the mass in a pendulum.

The filling unit shall be installed horizontally on a solid object. The impact of the mass shall be on the centre of the protruding part of the filling unit.

7.3.   Test interpretation

The filling unit shall comply with the external leak test and seat leak test at ambient temperature.

7.4.   Re-testing

If the filling unit fails the test, 2 samples of the same component shall be submitted to the impact test. If both samples pass the test, the first test shall be ignored.

In the event where one or both fail the re-test, the component shall not be approved.

Remarks:

Figure 1

Connecting area of the Bayonet filling unit

Figure 2

Connecting area of the Dish filling unit

Figure 3

Connecting area of the light vehicle Euro filling unit

Figure 4

Connecting area of the ACME filling unit

Figure 5

Connecting area of the heavy-duty vehicle Euro filling unit

Dimensions in millimetres

Keys:

(*1)  Only for non-metallic parts.

(*2)  Only for metallic parts.

ANNEX 10

PROVISIONS REGARDING THE APPROVAL OF LPG CONTAINERS

The meaning of symbols and terms used in this annex

1.   TECHNICAL REQUIREMENTS

1.1.   Cylinders covered by this annex are as follows

LPG-1 Metal containers

LPG-4 All-Composite containers

1.2.   Dimensions

For all dimensions without indication of tolerances, general tolerances of EN 22768-1 shall apply.

1.3.   Materials

1.3.1.   The material used for the manufacture of the stress-resistant container shells must be steel as specified in Euronorm EN 10120 (however, other materials may be used provided that the container has the same safety characteristics, to be certified by the authorities granting type approval).

1.3.2.   The parent material refers to the material in the state before any specific transformation with regards to the manufacturing process has been carried out.

1.3.3.   All components of the container body and all the parts welded thereto must be made of mutually compatible materials.

1.3.4.   The filler materials must be compatible with the parent material so as to form welds with properties equivalent to those specified for the parent material (EN 288-39).

1.3.5.   The container manufacturer must obtain and provide:

1.3.6.   The inspection authority must have the opportunity to make independent analyses. These analyses must be carried out either on specimens taken from the materials as supplied to the container manufacturer or on the finished containers.

1.3.7.   The manufacturer must make available to the inspection authority the results of metallurgical and mechanical tests and analyses of parent and filler materials carried out on welds and must also provide it with a description of the welding methods and processes which can be regarded as representative of the welds made during production.

1.4.   Design temperatures and pressures

1.4.1.   Design temperature

The design operating temperature of the container shall be from –20 °C to 65 °C. For extreme operating temperatures exceeding the above-mentioned temperatures special test conditions are applicable which shall be agreed upon with the competent authority.

1.4.2.   Design pressure

The design operating pressure of the container shall be: 3 000 kPa.

1.5.   The heat treatment procedures, on metal containers only, shall be according to the following requirements

1.5.1.   The heat treatment shall be carried out on the parts or on the complete container.

1.5.2.   Those parts of a container having been deformed by more than 5 per cent must be submitted to the following heat treatment: normalize.

Containers with a wall thickness ≥ 5 mm must be submitted to the following heat treatment:

1.5.3.1.   hot-rolled and normalized material: stress relieve or normalize;

1.5.3.2.   material of a different kind: normalize.

1.5.4.   The manufacturer must submit the procedure for the heat treatment used.

1.5.5.   Localized heat treatment of a completed container is not permitted.

1.6.   Calculation of the parts under pressure

Calculation of the parts under pressure for metal containers.

The wall thickness of the cylindrical shell of the containers must not be less than that calculated by the formula:

1.6.1.1.1.   Containers without longitudinal welds:

1.6.1.1.2.   Containers with longitudinal welds:

Dimensions and calculations of ends (see figures in Appendix 4 to this annex).

1.6.1.2.1.   The container ends shall be in one piece, shall encave to the pressure and shall have either a torispherical or an elliptical form (examples are given in Appendix 5).

1.6.1.2.2.   The container ends must fulfil the following conditions:

Torispherical ends

simultaneous limits:

Elliptical ends

simultaneous limits:

1.6.1.2.3.   The thickness of these barrelled ends must not in toto be less than the figure calculated by means of the following formula:

The shape factor C to be used for full ends is given in the table and in the graphs contained in Appendix 4 to this annex.

The wall thickness of the cylindrical edge of the ends may not be less or differ more than 15 per cent from the smallest wall thickness of the shell.

1.6.1.3.   The nominal wall thickness of the cylindrical part and of the barrelled end may not, under any circumstances; be less than:

with a minimum of 1,5 mm.

1.6.1.4.   The shell of the container may be made up of one, two or three parts. When the shell is made up from two or three parts, the longitudinal welds must be shifted/rotated with a minimum of 10 times the thickness of the container wall (10 · a). The ends must be in one piece and convex.

1.6.2.   Calculation of the parts under pressure for all-composite containers

The stresses in the container shall be calculated for each container type. The pressures used for these calculations shall be the design pressure and burst test pressure. The calculations shall use suitable analysis techniques to establish stress distribution throughout the container.

1.7.   Construction and workmanship

General requirements

1.7.1.1.   The manufacturer shall demonstrate by having a suitable quality control system that he has and maintains the manufacturing facilities and processes to ensure that containers produced satisfy the requirements of this annex.

1.7.1.2.   The manufacturer must ensure through adequate supervision that the parent materials and pressed parts used to manufacture the containers are free from defects likely to jeopardize the safe use of the containers.

Parts subjected to pressure

1.7.2.1.   The manufacturer must describe the welding methods and processes used and indicate the inspections carried out during production.

1.7.2.2.   Technical welding requirements

The butt welds must be executed by an automatic welding process.

The butt welds on the stress-resistant shell may not be located in any area where there are changes of profile.

Angle welds may not be superimposed on butt welds and must be at least 10 mm away from them.

Welds joining parts making up the shell of the container must satisfy the following conditions (see figures given as examples in Appendix 1 of this annex):

longitudinal weld: this weld is executed in the form of a butt weld on the full section of the material of the wall;

circumferential weld:

this weld is executed in the form of a butt weld on the full section of the material of the wall. A joggle weld is considered to be a special type of butt weld;

welds of the studded valve plate or ring shall be carried out according to Appendix 1, Figure 3.

A weld fixing the collar or supports to the container shall be either a butt or angle weld.

Welded mounting supports shall be welded in the circumferential way. The welds shall be strong enough to withstand vibration, braking actions and outside forces of at least 30 g in all directions.

In this case of butt welds, the misalignment of the joint faces may not exceed one-fifth of the thickness of the walls (1/5 a).

1.7.2.3.   Inspection of welds

The manufacturer must ensure that the welds show continuous penetration without any deviation of the weld seam, and that they are free from defects likely to jeopardize the safe use of the container.

For containers in two pieces, a radiographical test has to be performed on the circumferential butt welds over 100 mm, with the exception of the welds in conformity with joggle weld on page 1 of Appendix 1 of this annex. On one container selected at the beginning and end of each shift period from continuous production and, in the event of production being interrupted for a period of more than 12 hours, the first container welded should also be radiographed.

1.7.2.4.   Out-of-roundness

The out-of-roundness of the cylindrical shell of the container must be limited so that the difference between the maximum and minimum outside diameter of the same cross-section is not more than 1 per cent of the average of those diameters.

Fittings

1.7.3.1.   The supports must be manufactured and attached to the container body in such a way as not to cause dangerous concentrations of stresses or be conducive to the collection of water.

1.7.3.2.   The base of the container must be sufficiently strong and made of metal compatible with the type of steel used for the container. The form of the base must give the container sufficient stability.

The top edge of the base must be welded to the container in such a way as not to be conducive to the collection of water nor to allow water to penetrate between the base and the container.

1.7.3.3.   A reference mark shall be affixed on the containers to ensure their correct installation.

1.7.3.4.   Where fitted, identification plates must be fixed on to the stress resistant shell and shall not be removable. All the necessary corrosion prevention measures must be taken.

1.7.3.5.   The container shall have provisions to mount a gas-tight housing or kind of protection device over the container accessories.

1.7.3.6.   Any other material, however, may be used for the manufacture of the supports, provided that its strength is assured and that all risk of the container end corroding is eliminated.

Fire protection

1.7.4.1.   A container representative of the type of container, all accessories fitted on it and any added insulation or protective material, shall be covered by a bonfire test as specified in paragraph 2.6. of this annex.

2.   TESTS

Tables 1 and 2 below give an overview of the tests to be performed on the LPG containers on prototypes as well as during the production process according to their nature. All tests shall be performed at ambient temperature of 20 ± 5 °C, unless otherwise stated.

Table 1

Overview of tests to be performed on metal containers

Note 1: 6 containers shall be submitted for type approval.

Note 2: On one of these prototypes the volume of the container and the wall thickness of each part of the container shall be determined.

Table 2

Overview of tests to be performed on all-composite containers

2.1.   Mechanical tests

General requirements

Frequency of the mechanical tests

2.1.1.1.1.   The frequency of the tests for metal containers shall be: 1 container from each batch during production and for type testing, see Table 1.

Test pieces which are not flat shall be flattened by a cold process.

In test pieces containing a weld, the weld shall be machined to trim the surplus.

Metal containers shall be subjected to the tests as described in Table 1.

Test pieces from containers with one circumferential weld only (two sections) shall be taken from the places shown in Appendix 2, Figure 1.

Test pieces from containers with longitudinal and circumferential welds (three or more sections) shall be taken from the places shown in Appendix 2, Figure 2.

2.1.1.1.2.   The frequency of the tests for all-composite containers shall be:

2.1.1.2.   All the mechanical tests for checking the properties of the parent metal and welds of the stress-resistant shells of the container are carried out on test pieces taken from finished containers.

Types of tests and evaluation of test results

Each sample container is subjected to the following tests:

2.1.2.1.1.   Containers with longitudinal and circumferential welds (three sections) on test-pieces taken from the places shown in Figure 1 of Appendix 2 of this annex:

(ml, m2) A minimum of two macroscopic tests of valve boss/plate sections in case of the sidewall mounted valves referred to in paragraph 2.4.2. below.

2.1.2.1.2.   Containers with circumferential welds only (two sections) on test-pieces taken from the places shown in Figures 2a and 2b of Appendix 2 to this annex:

The tests as specified in paragraph 2.1.2.1.1. above with the exception of (c), (e) and (f) which are not applicable. The test-piece for the tensile test on parent material shall be taken from (a) or (b) as mentioned in paragraph 2.1.2.1.1. above.

2.1.2.1.3.   Test-pieces which are not sufficiently flat must be flattened by cold pressing.

2.1.2.1.4.   In all test pieces containing a weld, the weld is machined to trim the surplus.

Tensile test

Tensile test on parent metal

2.1.2.2.1.1.   The tensile test shall be carried out in accordance with Euronorms EN 876, EN 895 and EN 10002-1.

2.1.2.2.1.2.   The values determined for yield stress, tensile strength and elongation after break must comply with the characteristics of the metal as required in paragraph 1.3. of this annex.

Tensile test on welds

2.1.2.2.2.1.   This tensile test perpendicular to the weld must be carried out on a test-piece having a reduced cross-section 25 mm in width for a length extending up to 15 mm beyond the edges of the weld, as shown in Figure 2 of Appendix 3 to this annex.

Beyond this central part the width of the test-piece must increase progressively.

2.1.2.2.2.2.   The tensile strength value obtained must meet the minimum levels required by EN 10120.

Bend test

2.1.2.3.1.   The bend test shall be carried out in accordance with standards ISO 7438:2000 and ISO 7799:2000 and Euronorm EN 910 for welded parts. The bend tests shall be carried out on the inner surface in tension and the outer surface in tension.

2.1.2.3.2.   Cracks must not appear in the test-piece when it is bent round a mandrel as long as the inside edges are separated by a distance not greater than the diameter of the mandrel + 3a (see Figure 1 in Appendix 3 of this annex).

2.1.2.3.3.   The ratio (n) between the diameter of the mandrel and the thickness of the test piece must not exceed the values given in the following table:

Retesting for the tensile and bend tests

2.1.2.4.1.   Retesting is permitted for the tensile and bend test. A second test shall consist of two test pieces taken from the same container.

If the results of these tests are satisfactory, the first test shall be ignored.

In the event where one or both of the retests fail to meet the requirements, the batch shall be rejected.

2.2.   Burst test under hydraulic pressure

Test conditions

Containers subjected to this test must bear the inscriptions which it is proposed to affix on the section of the container subjected to pressure,

2.2.1.1.   The burst test under hydraulic pressure must be carried out with equipment which enables the pressure to be increased at an even rate, until the container bursts and the change in pressure over time to be recorded. The maximum flow rate during the test should not exceed 3 per cent of the capacity of the container per minute.

Test interpretation

The criteria adopted for the interpretation of the burst test are as follows:

2.2.2.1.1.   Volumetric expansion of the metal container; it equals: volume of water used between the time when the pressure starts to rise and the time of bursting;

2.2.2.1.2.   Examination of the tear and the shape of its edges;

2.2.2.1.3.   Bursting pressure.

Test acceptance conditions

2.2.3.1.   The measured bursting pressure (Pr) must not under any circumstances be less than 2,25 × 3 000 = 6 750 kPa.

2.2.3.2.   The specific change in the volume of the metal container at the time of bursting must not be less than:

20 per cent if the length of the metal container is greater than the diameter;

17 per cent if the length of the metal container is equal to or less than the diameter.

8 per cent in the case of a special metal container as shown in Appendix 5, page 1, Figures A, B and C.

The burst test must not cause any fragmentation of the container.

2.2.3.3.1.   The main fracture must not show any brittleness, i.e. the edges of the fracture must not be radial but must be at an angle to a diametrical plane and display a reduction of area throughout their thickness.

2.2.3.3.2.   For metal containers the fracture must not reveal an inherent defect in the metal. The weld must be at least as strong as the original metal but preferably stronger.

For all-composite containers, the fracture shall not reveal any defects in the structure.

2.2.3.4.   Retesting for the burst test

Retesting is permitted for the burst test. A second burst test shall be performed on two containers which have been produced successively to the first container within the same batch.

If the results of these tests are satisfactory, the first test shall be ignored.

In the event where one or both of the retests fail to meet the requirements, the batch shall be rejected.

2.3.   Hydraulic test

2.3.1.   The containers representative of the type of container submitted for approval (without accessories but with the outlets closed off) shall withstand an inner hydraulic pressure of 3 000 kPa without leakages or becoming permanently distorted, according to the following requirements:

2.3.2.   The water pressure in the container must increase at an even rate until the test pressure of 3 000 kPa is reached.

2.3.3.   The container must remain under the test pressure long enough to make it possible to establish that the pressure is not falling off and that the container can be guaranteed leakproof.

2.3.4.   After the test the container must show no signs of permanent deformation.

2.3.5.   Any container tested which does not pass the test must be rejected.

Additional hydraulic tests to be performed on all-composite containers

Ambient temperature pressure cycling test

2.3.6.1.1.   Test procedure

The finished container shall be pressure cycled to a maximum of 20 000 cycles, according to the following procedure:

2.3.6.1.2.   Test interpretation

Before reaching 10 000 cycles, the container shall not fail or leak.

After completing 10 000 cycles, the container may leak before break.

2.3.6.1.3.   Retesting

Retesting is permitted for the ambient temperature pressure cycling test.

A second test shall be performed on two containers which have been produced successively to the first container within the same batch.

If the results of these tests are satisfactory, the first test shall be ignored.

In the event where one or both of the retests fail to meet the requirements, the batch shall be rejected.

+High temperature pressure cycling test

2.3.6.2.1.   Test procedure

Finished containers shall be cycle tested, without showing evidence of rupture, leakage, or fibre unravelling, as follows:

Following the pressure cycling at high temperature, containers shall be submitted to the external leak test and then hydrostatically pressurized to failure in accordance with the burst test procedure.

2.3.6.2.2.   Test interpretation

The container shall comply with the external leak test requirements as defined in paragraph 2.3.6.3.

The container shall achieve a minimum burst pressure of 85 per cent of the burst pressure.

2.3.6.2.3.   Retesting

Retesting is permitted for the high temperature pressure cycling test.

A second test shall be performed on two containers which have been produced successively to the first container within the same batch.

If the results of these tests are satisfactory, the first test shall be ignored.

In the event where one or both of the retests fail to meet the requirements, the batch shall be rejected.

External leak test

2.3.6.3.1.   Test procedure

While under 3 000 kPa pressure, the container shall be submerged in soapy water to detect leakage (bubble test).

2.3.6.3.2.   Test interpretation

The container shall not show any leakage.

2.3.6.3.3.   Retesting

Retesting is permitted for the external leak test.

A second test shall be performed on two containers which have been produced successively to the first container within the same batch.

If the results of these tests are satisfactory, the first test shall be ignored. In the event where one or both of the retests fail to meet the requirements, the batch shall be rejected.

Permeation test

2.3.6.4.1.   Test procedure

All the tests shall be performed at 40 °C on a container fuelled with commercial propane at 80 per cent of its water capacity.

The test shall be held during at least 8 weeks until the steady state permeation of the structure is observed during at least 500 hours.

Then, the rate of the container weight loss shall be measured.

The graph of mass change per number of days shall be recorded.

2.3.6.4.2.   Test interpretation

The rate of mass loss shall be less than 0,15 g/hour.

2.3.6.4.3.   Retesting

Retesting is permitted for the permeation test.

A second test shall be performed on two containers which have been produced successively to the first container within the same batch.

If the results of these tests are satisfactory, the first test shall be ignored. In the event where one or both of the retests fail to meet the requirements, the batch shall be rejected.

LPG cycling test

2.3.6.5.1.   Test procedure

A container having successfully passed the permeation test shall be submitted to an ambient temperature pressure cycling test according to the requirements of paragraph 2.3.6.1. of this annex.

The container shall be sectioned and the liner/end boss interface shall be inspected.

2.3.6.5.2.   Test interpretation

The container shall comply with the ambient temperature pressure cycling test requirements.

Inspection of the liner/end boss interface of the container shall not reveal any evidence of deterioration, such as fatigue cracking or electrostatic discharge.

2.3.6.5.3.   Retesting

Retesting is permitted for the LPG cycling test.

A second test shall be performed on two containers which have been produced successively to the first container within the same batch.

If the results of these tests are satisfactory, the first test shall be ignored.

In the event where one or both of the retests fail to meet the requirements, the batch shall be rejected.

High temperature creep test

2.3.6.6.1.   General

This test shall only be performed on all-composite containers with a resin matrix having a glass transition temperature (TG) below the design temperature +50 °C.

2.3.6.6.2.   Test procedure

One finished container shall be tested as follows:

2.3.6.6.3.   Test interpretation

The maximum allowed volume increase is 5 per cent. The container shall meet the requirements of the external leak test as defined in paragraph 2.4.3. of this annex and the burst test as defined in paragraph 2.2. of this annex.

2.3.6.6.4.   Retesting

Retesting is permitted for the high temperature creep test.

A second test shall be performed on two containers which have been produced successively to the first container within the same batch.

If the results of these tests are satisfactory, the first test shall be ignored.

In the event where one or both of the retests fail to meet the requirements, the batch shall be rejected.

2.4.   Non-destructive examination

Radiographic examination

2.4.1.1.   Welds must be radiographed in compliance with ISO specification R 1106, using classification B.

2.4.1.2.   When a wire-type indicator is used, the smallest diameter of the wire visible may not exceed the value of 0,10 mm.

When a stepped and holed type indicator is used, the diameter of the smallest hole visible may not exceed 0,25 mm.

2.4.1.3.   Assessment of the weld radiographs must be based on the original films in compliance with the practice recommended in standard ISO 2504, paragraph 6.

The following defects are not acceptable:

Cracks, inadequate welds or inadequate penetration of the weld.

2.4.1.4.1.   For the container wall thickness ≥ 4 mm, the inclusions listed below are regarded as acceptable:

Any gas inclusion measuring not more than a/4 mm;

Any gas inclusion measuring more than a/4 mm but not more than a/3 mm, which is more than 25 mm away from other gas inclusion measuring more than a/4 mm and measuring not more than a/3 mm;

Any elongated inclusion or any group of rounded inclusions in a row where the length represented (over a weld length of 12a) is not greater than 6 mm;

Gas inclusions over any 100 mm weld length, where the total area of all the figures is not greater than 2a mm2.

2.4.1.4.2.   For the container wall thickness < 4 mm, the inclusions listed below are regarded as acceptable:

Any gas inclusion measuring not more than a/2 mm;

Any gas inclusion measuring more than a/2 mm but not more than a/1,5 mm, which is more than 25 mm away from other gas inclusion measuring more than a/2 mm and measuring not more than a/1,5 mm;

Any elongated inclusion or any group of rounded inclusions in a row where the length represented (over a weld length of 12a) is not greater than 6 mm;

Gas inclusions over any 100 mm weld length, where the total area of all the figures is not greater than 2a mm2.

2.4.2.   Macroscopic examination

The macroscopic examination of a full transverse section of the weld must show a complete fusion on the surface treated with any acid from the macro-preparation and must not show any assembly fault or a significant inclusion or other defects.

In case of doubt, a microscopic examination should be made of the suspect area.

2.5.   Examination on the outside of the weld for metal containers

2.5.1.   This examination is carried out when the weld has been completed.

The welded surface examined must be well illuminated, and must be free from grease, dust, scale residue or protective coating of any kind.

2.5.2.   The fusion of the welded metal with the parent metal must be smooth and free from etching. There must be no cracks, notching or porous patches in the welded surface and the surface adjacent to the wall. The welded surface must be regular and even. Where a butt weld has been used, the excess thickness must not exceed 1/4 of the width of the weld.

2.6.   Bonfire test

2.6.1.   General

The bonfire test is designed to demonstrate that a container complete with the fire protection system, specified in the design, will prevent the burst of the container when tested under the specified fire conditions. The manufacturer shall describe the behaviour of the complete fire protection system including the designed drop to atmospheric pressure. The requirements of this test shall be deemed to be fulfilled for any container having the following characteristics in common with the parent container:

2.6.2.   Container set-up

Containers with a length equal to or larger than 1,65 m: If the container is fitted with a pressure relief device at one side, the fire source shall commence at the opposite side of the container. If the container is fitted with pressure relief devices at both sides, or at more than one location along the length of the container, the centre of the fire source shall be centred midway between the pressure relief devices that are separated by the greatest horizontal distance.

2.6.3.   Fire source

A uniform fire source of 1,65 m length shall provide direct flame impingement on the container surface across its entire diameter.

Any fuel may be used for the fire source provided that it supplies uniform heat sufficient to maintain the specified test temperatures until the container is vented. The arrangement of the fire shall be recorded in sufficient detail to ensure that the rate of heat input to the container is reproducible. Any failure or inconsistency of the fire source during a test shall invalidate the result.

2.6.4.   Temperature and pressure measurements

During the bonfire test the following items shall be measured:

Metallic shielding shall be used to prevent direct flame impingement on the thermocouples. Alternatively, thermocouples may be inserted into blocks of metal, measuring less than 25 mm2. During the test the thermocouple temperatures and the container pressure shall be recorded at intervals of 2 seconds or less.

2.6.5.   General test requirements

2.6.6.   Test results:

2.7.   Impact test

2.7.1.   General

At the choice of the manufacturer, all the impact tests may be carried out on one container or each may be carried out on a different container.

Test procedure

For this test, the fluid medium shall be water/glycol mixture or another liquid having a low freezing point which does not change the properties of the container material.

A container filled with the fluid medium to the weight that equals the filling with 80 per cent of LPG with a reference mass of 0,568 kg/l, is projected, parallel to the length axle (x-axis in Figure 1) of the vehicle in which it is intended to be fitted at a velocity, V of 50 km/h, against a solid wedge, fixed horizontally, perpendicular to the movement of the container.

The wedge shall be installed so that the centre of gravity (c.g.) of the container hits the centre of the wedge.

The wedge shall have an angle α of 90 degrees and the point of impact shall be rounded with a maximum radius of 2,5 mm. The length of the wedge L, shall be at least equal to the width of the container in respect to its movement during the test. The height H of the wedge shall be at least 600 millimetres

Figure 1

description of the impact test procedure:

Note: c.g. = center of gravity

c.g.

c.g.

In the case where a container can be installed in more than one position in the vehicle, each position shall be tested.

After this test, the container shall be submitted to an external leak test as defined in paragraph 2.3.6.3. of this annex.

2.7.3.   Test interpretation

The container shall comply with the external leak test requirements as defined in paragraph 2.3.6.3. of this annex.

2.7.4.   Retesting

Retesting is permitted for the impact test.

A second test shall be performed on two containers which have been produced successively to the first container within the same batch.

If the results of these tests are satisfactory, the first test shall be ignored.

In the event where one or both of the retests fail to meet the requirements, the batch shall be rejected.

2.8.   Drop Test

2.8.1.   Test procedure

One finished container shall be drop tested at ambient temperature without internal pressurization or attached valves. The surface onto which the containers are dropped shall be a smooth, horizontal concrete pad or flooring.

The drop height (Hd) shall be 2 m (measured to the lowest point of the container).

The same empty container shall be dropped:

Following the drop test, the containers shall be submitted to an ambient temperature pressure cycling test according the requirements of paragraph 2.3.6.1. of this annex.

2.8.2.   Test interpretation

The containers shall comply with the requirements of the ambient temperature pressure cycling test according the requirements of paragraph 2.3.6.1. of this annex.

2.8.3.   Retesting

Retesting is permitted for the drop test.

A second test shall be performed on two containers which have been produced successively to the first container within the same batch.

If the results of these tests are satisfactory, the first test shall be ignored.

In the event where one or both of the retests fail to meet the requirements, the batch shall be rejected.

2.9.   Boss torque test

2.9.1.   Test procedure

The body of the container shall be restrained against rotation and a torque of 2 times the valve or PRD installation torque specified by the manufacturer shall be applied to each end boss of the container, first in the direction to tighten a threaded connection, then in the untightening direction, and finally again in the tightening direction.

The container shall then be subjected to an external leak test in accordance with the requirements shown in paragraph 2.3.6.3 of this annex.

2.9.2.   Test interpretation

The container shall comply with the requirements of the external leak test as shown in paragraph 2.3.6.3. of this annex.

2.9.3.   Retesting

Retesting is permitted for the boss torque test.

A second test shall be performed on two containers which have been produced successively to the first container within the same batch.

If the results of these tests are satisfactory, the first test shall be ignored.

In the event where one or both of the retests fail to meet the requirements, the batch shall be rejected.

2.10.   Acid environment test

2.10.1.   Test procedure

A finished container shall be exposed for 100 hours to a 30 per cent sulphuric acid solution (battery acid with specific gravity of 1,219) while pressurized to 3 000 kPa. During the test, a minimum of 20 per cent of the total area of the container has to be covered by the sulphuric acid solution.

Then, the container shall be submitted to a burst test as defined in paragraph 2.2. of this annex.

2.10.2.   Test interpretation

The burst pressure measured shall be at least 85 per cent of the container burst pressure.

2.10.3.   Retesting

Retesting is permitted for the acid environment test.

A second test shall be performed on two containers which have been produced successively to the first container within the same batch.

If the results of these tests are satisfactory, the first test shall be ignored.

In the event where one or both of the retests fail to meet the requirements, the batch shall be rejected.

2.11.   Ultra-violet (UV) test

2.11.1.   Test procedure

When the container is directly subjected to sunlight (also behind glass), UV-radiation might degrade polymeric materials. Therefore, the manufacturer has to prove the ability of the outer layer material to withstand the UV-radiation during his lifetime of 20 years.

2.11.2.   Test interpretation

When the outer layer has a mechanical function, the container shall comply with the burst test requirements as defined in paragraph 2.2. of this annex.

2.11.3.   Retesting

Retesting is permitted for the ultra-violet test.

A second test shall be performed on two containers which have been produced successively to the first container within the same batch.

If the results of these tests are satisfactory, the first test shall be ignored.

In the event where one or both of the retests fail to meet the requirements, the batch shall be rejected.

(1)  These test pieces can be taken from one container

(2)  Additional accessories, modifications and extensions of the accessories fitted to the container is possible without retesting, if notified to the administrative department which approved the container, considered to be unlikely to have an appreciable adverse effect. The administrative department may require a further test report from the technical service responsible. The container and its configurations of accessories will be indicated in Appendix 1 to Annex 2B.

ANNEX 11

PROVISIONS REGARDING THE APPROVAL OF GAS INJECTION DEVICES, OR GAS MIXING PIECES, OR INJECTORS AND THE FUEL RAIL

Gas injection device or injector

1.1.   Definition: see paragraph 2.10. of this Regulation.

1.2.   Component classification (according to Figure 1, para. 2.): Class 1.

1.3.   Classification pressure: 3 000 kPa.

1.4.   Design temperatures:

–20 °C to 120 °C

For temperatures exceeding the above-mentioned values, special tests conditions are applicable.

1.5.   General design rules:

Paragraph 6.15.2., Provisions regarding the electrical insulation.

Paragraph 6.15.2.1., Provisions regarding the insulation class.

Paragraph 6.15.3.1., Provisions when the power is switched off.

Paragraph 6.15.4.1., Heat exchange medium (compatibility and pressure requirements).

1.6.   Applicable test procedures:

Gas injection device or gas mixing piece

2.1.   Definition: see paragraph 2.10. of this Regulation.

2.2.   Component classification (according to Figure 1, para. 2.):

2.3.   Classification pressure:

2.4.   Design temperatures:

–20 °C to 120 °C, when the fuel pump is mounted outside the container.

For temperatures exceeding the above-mentioned values, special tests conditions are applicable.

2.5.   General design rules:

Paragraph 6.15.2., Provisions regarding the electrical insulation.

Paragraph 6.15.2.1., Provisions regarding the insulation class.

Paragraph 6.15.3.1., Provisions when the power is switched off.

Paragraph 6.15.4.1., Heat exchange medium (compatibility and pressure requirements).

2.6.   Applicable test procedures:

Fuel rail

3.1.   Definition: see paragraph 2.18. of this Regulation.

3.2.   Component classification (according to Figure 1, para. 2.):

Fuel rails can be of Class 1, 2 or 2A.

3.3.   Classification pressure:

3.4.   Design temperatures:

–20 °C to 120 °C

For temperatures exceeding the above-mentioned values, special tests conditions are applicable.

3.5.   General design rules: (not used)

Applicable test procedures:

3.6.1.   For fuel rails of Class 1:

3.6.2.   For fuel rails of Class 2 and/or 2A:

(*1)  Only for non-metallic parts.

(*2)  Only for metallic parts.

ANNEX 12

PROVISIONS REGARDING THE APPROVAL OF THE GAS DOSAGE UNIT WHEN NOT COMBINED WITH THE GAS INJECTION DEVICE(S)

1.   Definition: see paragraph 2.11. of this Regulation.

2.   Component classification (according to Figure 1, para. 2.):

3.   Classification pressure:

4.   Design temperatures:

–20 °C to 120 °C

For temperatures exceeding the above-mentioned values, special tests conditions are applicable.

5.   General design rules:

Paragraph 6.15.2., Provisions regarding the electrical insulation.

Paragraph 6.15.3.1., Provisions on valves activated by electrical power.

Paragraph 6.15.4., Heat exchange medium (compatibility and pressure requirements).

Paragraph 6.15.5., Overpressure bypass security.

6.   Applicable test procedures:

Remarks:

The parts of the gas dosage unit (Class 2 or 2A) shall be leakproof with the outlet(s) of that part closed.

For the overpressure test all the outlets including those of the coolant compartment shall be closed off.

(*1)  Only for non-metallic parts.

(*2)  Only for metallic parts.

ANNEX 13

PROVISIONS REGARDING THE APPROVAL OF THE PRESSURE AND/OR TEMPERATURE SENSOR

1.   Definition:

Pressure sensor: see paragraph 2.13. of this Regulation.

Temperature sensor: see paragraph 2.13. of this Regulation.

2.   Component classification (according to Figure 1, para. 2.):

Pressure and temperature sensors can be of Class 1, 2 or 2A.

3.   Classification pressure:

4.   Design temperatures:

–20 °C to 120 °C

For temperatures exceeding the above-mentioned values, special tests conditions are applicable.

5.   General design rules:

Paragraph 6.15.2., Provisions regarding the electrical insulation.

Paragraph 6.15.4.1., Heat exchange medium (compatibility and pressure requirements).

Paragraph 6.15.6.2., Gas flow prevention.

Applicable test procedures:

6.1.   For parts of Class 1:

6.2.   For parts of Class 2 or 2A:

(*1)  Only for non-metallic parts.

(*2)  Only for metallic parts.

ANNEX 14

PROVISIONS REGARDING THE APPROVAL OF THE ELECTRONIC CONTROL UNIT

1.   The electronic control unit can be any device which controls the LPG demand of the engine and establishes the cut-off of the remotely-controlled service valve(s), cut-off valves and fuel pump of the LPG-system in case of a broken fuel supply pipe or/and in case of stalling of the engine.

2.   The switching off delay of the service cut-off valves after stalling of the engine may not be more then 5 seconds.

3.   The electronic control unit shall comply with relevant electromagnetic compatibility (EMC) requirements according to Regulation No 10, 02 series of amendments or equivalent.

4.   Electrical failure of the vehicle system may not lead to uncontrolled opening of any valve.

5.   The output of the electronic control unit shall be inactive when the electric power is switched off or removed.

ANNEX 15

TEST PROCEDURES

1.   Classification

1.1.   LPG components for use in vehicles shall be classified with regard to the maximum operating pressure and function, according to Chapter 2 of this Regulation.

1.2   The classification of the components determines the tests which have to be performed for type approval of the components or parts of the components.

2.   Applicable test procedures

In Table 1 the applicable test procedures dependent on the classification are shown.

Table 1