Only the original UN/ECE texts have legal effect under international public law. The status and date of entry into force of this Regulation should be checked in the latest version of the UN/ECE status document TRANS/WP.29/343, available at: http://www.unece.org/trans/main/wp29/wp29wgs/wp29gen/wp29fdocstts.html.

Regulation No 67 of the Economic Commission for Europe of the United Nations (UN/ECE) — Uniform provisions concerning:

I.

Approval of specific equipment of motor vehicles using liquefied petroleum gases in their propulsion system;

II.

Approval of a vehicle fitted with specific equipment for the use of liquefied petroleum gases in its propulsion system with regard to the installation of such equipment

Addendum 66: Regulation No 67

Supplement 7 to the 01 series of amendments — Date of entry into force: 2 February 2007

CONTENTS

REGULATION

1.

Scope

2.

Definition and classification of components

PART I

3.

Application for approval

4.

Markings

5.

Approval

6.

Specifications regarding the various components of the LPG equipment

7.

Modifications of a type of LPG equipment and extension of approval

8.

(Not allocated)

9.

Conformity of production

10.

Penalties for non-conformity of production

11.

Transitional provisions regarding the various components of the LPG equipment

12.

Production definitely discontinued

13.

Names and addresses of technical services responsible for conducting approval tests and of administrative departments

PART II

14.

Definitions

15.

Application for approval

16.

Approval

17.

Requirements for the installation of specific equipment for the use of liquefied petroleum gases in the propulsion system of a vehicle

18.

Conformity of production

19.

Penalties for non-conformity of production

20.

Modification and extension of approval of a vehicle type

21.

Production definitely discontinued

22.

Transitional provisions regarding the installation of various components of the LPG equipment and the type approval of a vehicle fitted with specific equipment for the use of liquefied petroleum gas in its propulsion system with regard to the installation of such equipment

23.

Names and addresses of technical services responsible for conducting approval tests, and of administrative departments

ANNEXES

Annex 1 —

Essential characteristics of the vehicle, engine and LPG-related equipment

Annex 2A —

Arrangement of the LPG equipment type-approval mark

Annex 2B —

Communication concerning the approval or extension or refusal or withdrawal of approval or production definitely discontinued of a type of LPG equipment pursuant to Regulation No 67

Annex 2C —

Arrangement of approval marks

Annex 2D —

Communication concerning the approval or extension or refusal or withdrawal of approval or production definitely discontinued of a vehicle type with regard to the installation of LPG systems pursuant to Regulation No 67

Annex 3 —

Provisions regarding the approval of LPG container accessories

Annex 4 —

Provisions regarding the approval of the fuel pump

Annex 5 —

Provisions regarding the approval of the LPG filter unit

Annex 6 —

Provisions regarding the approval of the pressure regulator and the vaporizer

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

Annex 8 —

Provisions regarding the approval of flexible hoses with couplings

Annex 9 —

Provisions regarding the approval of the filling unit

Annex 10 —

Provisions regarding the approval of LPG containers

Annex 11 —

Provisions regarding the approval of gas injection devices, or gas mixing pieces, or injectors and the fuel rail

Annex 12 —

Provisions regarding the approval of the gas dosage unit when not combined with the gas injection device(s)

Annex 13 —

Provisions regarding the approval of the pressure and/or temperature sensor

Annex 14 —

Provisions regarding the approval of the electronic control unit

Annex 15 —

Test procedures

Annex 16 —

Provisions regarding LPG identification mark for M

2

and M

3

category vehicles

Annex 17 —

Provisions regarding identification mark for service couplings

1.   SCOPE

This Regulation applies to:

Part I.

Approval of specific equipment of vehicles of category M and N(1) using liquefied petroleum gases in their propulsion system;

Part II.

Approval of vehicles of category M and N(1) fitted with specific equipment for the use of liquefied petroleum gases in their propulsion system with regard to the installation of such equipment.

2.   DEFINITION AND CLASSIFICATION OF COMPONENTS

LPG components for use in vehicles shall be classified with regard to the maximum operating pressure and function, according to Figure 1.

Class 1

High pressure parts including tubes and fittings containing liquid LPG at vapour pressure or increased vapour pressure up to 3 000 kPa.

Class 2

Low pressure parts including tubes and fittings containing vaporized LPG with a maximum operating pressure below 450 kPa and over 20 kPa above atmospheric pressure.

Class 2A

Low pressure parts for a limited pressure range including tubes and fittings containing vaporized LPG with a maximum operating pressure below 120 kPa and over 20 kPa above atmospheric pressure.

Class 3

Shut-off valves and pressure relief valves, when operating in the liquid phase.

LPG components designed for a maximum operating pressure below 20 kPa above atmospheric pressure are not subjected to this Regulation.

A component can consist of several parts, each part classified in his own class with regard to maximum operating pressure and function.

Figure 1

Classification with regard to maximum operating pressure and function

[Bild bitte in Originalquelle ansehen]

‘Pressure’ means relative pressure versus atmospheric pressure, unless otherwise stated.

2.1.1.   ‘Service pressure’ means the settled pressure at a uniform gas temperature of 15 °C.

2.1.2.   ‘Test pressure’ means the pressure to which the component is subjected during the approval test.

2.1.3.   ‘Working pressure’ means the maximum pressure to which the component is designed to be subjected and on the basis of which its strength is determined.

2.1.4.   ‘Operating pressure’ means the pressure under normal operating conditions.

2.1.5.   ‘Maximum operating pressure’ means the maximum pressure in a component which might arise during operation.

2.1.6.   ‘Classification pressure’ means the maximum allowable operating pressure in a component according to its classification.

2.2.   ‘Specific equipment’ means:

(a) the container,

(b) the accessories fitted to the container,

(c) the vaporizer/pressure regulator,

(d) the shut-off valve,

(e) the gas injection device or injector or gas mixing piece,

(f) the gas dosage unit, either separate or combined with the gas injection device,

(g) flexible hoses,

(h) filling unit,

(i) non-return valve,

(j) gas-tube pressure relief valve,

(k) filter unit,

(l) pressure or temperature sensor,

(m) fuel pump,

(n) service coupling,

(o) electronic control unit,

(p) fuel rail,

(q) pressure relief device;

‘Container’ means any vessel used for the storage of liquefied petroleum gas;

2.3.1.   A container can be:

(i) a standard cylindrical container with a cylindrical shell, two dished ends either torispherical or elliptical and the required openings;

(ii) a special container: other containers than standard cylindrical containers. The dimensional characteristics are given in Annex 10, Appendix 5;

2.3.2.   ‘All-composite container’ means a container made only of composite materials with a non metallic liner.

2.3.3.   ‘Batch of containers’ means a maximum of 200 containers of the same type produced consecutively on the same production line.

2.4.   ‘Type of container’ means containers which do not differ in respect to the following characteristics as specified in Annex 10:

(a) the trade name(s) or trade mark(s),

(b) the shape (cylindrical, special shape),

(c) the openings (plate for accessories/metal ring),

(d) the material,

(e) the welding process (in case of metal containers),

(f) the heat treatment (in case of metal containers),

(g) the production line,

(h) the nominal wall thickness,

(i) the diameter

(j) the height (in case of special containers)

‘Accessories fitted to the container’ means the following equipment which may be either separate or combined:

(a) 80 per cent stop valve

(b) level indicator

(c) pressure relief valve

(d) remotely controlled service valve with excess flow valve

(e) fuel pump

(f) multivalve

(g) gas-tight housing

(h) power supply bushing

(i) non-return valve

(j) pressure relief device

2.5.1.   ‘80 per cent stop valve’ means a device that limits the filling at maximum 80 per cent of the capacity of the container;

2.5.2.   ‘Level indicator’ means a device to verify the level of liquid in the container;

‘Pressure relief valve (discharge valve)’ means a device to limit the pressure build-up in the container;

2.5.3.1.   ‘Pressure relief device’ means a device aimed to protect the container from burst which can occur in case of fire, by venting the LPG contained;

2.5.4.   ‘Remotely controlled service valve with excess flow valve’ means a device which allows the establishment and interruption of LPG supply to the evaporator/pressure regulator; remotely controlled means that the service valve is controlled by the electronic control unit; when the engine of the vehicle is not running the valve is closed; an excess flow valve means a device to limit the flow of LPG;

2.5.5.   ‘Fuel pump’ means a device to establish the supply of liquid LPG to the engine by increasing the pressure of the container with the fuel pump supply pressure;

2.5.6.   ‘Multivalve’ means a device consisting of all or part of the accessories mentioned in paragraphs 2.5.1. to 2.5.3. and 2.5.8.;

2.5.7.   ‘Gas-tight housing’ means a device to protect the accessories and to vent any leakages to the open air;

2.5.8.   power supply bushing (fuel pump/actuators/fuel level sensor);

2.5.9.   ‘Non-return valve’ means a device to allow the flow of liquid LPG in one direction and to prevent the flow of liquid LPG in the opposite direction;

2.6.   ‘Vaporizer’ means a device intended to vaporize LPG from a liquid to a gaseous state;

2.7.   ‘Pressure regulator’ means a device intended for reducing and regulating the pressure of liquefied petroleum gas;

2.8.   ‘Shut-off valve’ means a device to cut off the flow of LPG;

2.9.   ‘Gas-tube pressure relief valve’ means a device to prevent the pressure build up in the tubes above a pre-set value;

2.10.   ‘Gas injection device or injector or gas mixing piece’ means a device which establishes the liquid or vaporized LPG to enter the engine;

2.11.   ‘Gas dosage unit’ means a device which meters and/or distributes the gas flow to the engine and can be either combined with the gas injection device or separate.

2.12.   ‘Electronic control unit’ means a device which controls the LPG demand of the engine and cuts off automatically the power to the shut-off valves of the LPG-system in case of a broken fuel supply pipe caused by an accident, or by stalling of the engine;

2.13.   ‘Pressure or temperature sensor’ means a device which measures pressure or temperature;

2.14.   ‘LPG filter unit’ means a device which filters the LPG, the filter can be integrated in other components;

2.15.   ‘Flexible hoses’ means hoses for conveying liquefied petroleum gas in either a liquid or vapour state at various pressures from one point to another;

2.16.   ‘Filling unit’ means a device to allow filling of the container; the filling unit can be realised by integration in the 80 per cent stop valve of the container or by a remote filling unit at the outside of the vehicle;

2.17.   ‘Service coupling’ means a coupling in the fuel line between the fuel container and the engine. If a mono-fuel vehicle is out of fuel the engine can be operated by means of a service fuel container which can be coupled to the service coupling;

2.18.   ‘Fuel rail’ means a pipe or duct that connects the fuel injection devices;

2.19.   ‘Liquefied petroleum gas (LPG)’ means any product essentially composed of the following hydrocarbons: propane, propene (propylene), normal butane, isobutane, isobutylene, butene (butylene) and ethane.

European Standard EN 589:1993 specifies requirements and methods of test for automotive LPG as marketed and delivered in the countries of the members of CEN (European Committee for Standardization).

PART I

APPROVAL OF SPECIFIC EQUIPMENT OF MOTOR VEHICLES USING LIQUEFIED PETROLEUM GASES IN THEIR PROPULSION SYSTEM

3.   APPLICATION FOR APPROVAL

3.1.   The application for approval of specific equipment shall be submitted by the holder of the trade name or mark or by his duly accredited representative.

It shall be accompanied by the undermentioned documents in triplicate and by the following particulars:

3.2.1.   a detailed description of the type of the specific equipment (as specified in Annex 1),

3.2.2.   a drawing of the specific equipment, sufficiently detailed and on an appropriate scale,

3.2.3.   verification of compliance with the specifications prescribed in paragraph 6. of this Regulation;

3.3.   At the request of the technical service responsible for conducting approval tests, samples of the specific equipment shall be provided.

Supplementary samples shall be supplied upon request.

4.   MARKINGS

4.1.   All components submitted for approval shall bear the trade name or mark of the manufacturer and the type; and for non-metallic components also the manufacturing month and year; this marking shall be clearly legible and indelible.

4.2.   All equipment shall have a space large enough to accommodate the approval mark including the classification of the component (see Annex 2A); this space shall be shown on the drawings referred to in paragraph 3.2.2. above.

4.3.   Every container shall also bear a marking plate, welded to it, with the following data clearly legible and indelible:

(a) a serial number;

(b) the capacity in litres;

(c) the marking ‘LPG’;

(d) test pressure [kPa];

(e) the wording: ‘maximum degree of filling: 80 %’;

(f) year and month of approval (e.g. 99/01);

(g) approval mark according to paragraph 5.4.

(h) the marking ‘PUMP INSIDE’ and a marking identifying the pump when a pump is mounted in the container.

5.   APPROVAL

5.1.   If the equipment samples submitted for approval meet the requirements of paragraphs 6.1. to 6.13. of this Regulation, approval of the type of equipment shall be granted.

5.2.   An approval number shall be assigned to each type of equipment approved. Its first two digits (at present 01 corresponding to the 01 series of amendments which entered into force on 13 November 1999) shall indicate the series of amendments incorporating the most recent major technical amendments made to the Regulation at the time of issue of the approval. The same Contracting Party shall not assign this alphanumeric code to another type of equipment.

5.3.   Notice of approval or of refusal or of extension of approval of an LPG equipment type/part pursuant to this Regulation shall be communicated to the Parties to the Agreement applying this Regulation, by means of a form conforming to the model in Annex 2B to this Regulation. If it concerns a container, Annex 2B — Appendix 1 shall be added.

There shall be affixed, conspicuously and in the space referred to in paragraph 4.2. above, to all equipment conforming to a type approved under this Regulation, in addition to the mark prescribed in paragraphs 4.1. and 4.3., an international approval mark consisting of:

5.4.1.   A circle surrounding the letter ‘E’ followed by the distinguishing number of the country which has granted approval(2).

5.4.2.   The number of this Regulation, followed by the letter ‘R’, a dash and the approval number to the right of the circle prescribed in paragraph 5.4.1. This approval number consists of the component type approval number which appears on the certificate completed for this type (see paragraph 5.2. and Annex 2B) preceded by two figures indicating the sequence of the latest series of amendments to this Regulation.

5.5.   The approval mark shall be clearly legible and be indelible.

5.6.   Annex 2A to this Regulation gives examples of the arrangement of the aforesaid approval mark.

6.   SPECIFICATIONS REGARDING THE VARIOUS COMPONENTS OF THE LPG EQUIPMENT

6.1.   General provisions

The specific equipment of vehicles using LPG in their propulsion system shall function in a correct and safe way.

The materials of the equipment which are in contact with LPG shall be compatible with it.

Those parts of equipment whose correct and safe functioning is liable to be influenced by LPG, high pressure or vibrations has to be submitted to relevant test procedures described in the annexes of this Regulation. In particular the provisions of paragraphs 6.2. to 6.13. are to be fulfilled.

The installation of LPG-equipment approved by this regulation shall comply with relevant electromagnetic compatibility (E.M.C) requirements according to Regulation No 10, 02 series of amendments, or equivalent.

6.2.   Provisions regarding containers

The LPG containers shall be type-approved pursuant to the provisions laid down in Annex 10 to this Regulation.

6.3.   Provisions regarding accessories fitted to the container

The container shall be equipped with the following accessories, which may be either separate or combined (multivalve(s)):

6.3.1.1.   80 per cent stop valve,

6.3.1.2.   level indicator,

6.3.1.3.   pressure relief valve (discharge valve),

6.3.1.4.   remotely controlled service valve with excess flow valve,

6.3.2.   The container may be equipped with a gas-tight housing, if necessary.

6.3.3.   The container may be equipped with a power supply bushing for the sake of actuators/LPG fuel pump.

6.3.4.   The container may be equipped with a LPG fuel pump inside the container.

6.3.5.   The container may be equipped with a non-return valve.

6.3.6.   The container shall be equipped with a pressure relief device (PRD). Devices or functions may be approved as PRD being:

(a) A fusible plug (temperature triggered) (fuse), or

(b) A pressure relief valve provided that it complies to paragraph 6.15.8.3., or

(c) A combination of the two above devices, or

(d) Any other equivalent technical solution, provided that it ensures the same degree of performance.

6.3.7.   The accessories mentioned in paragraphs 6.3.1. to 6.3.6. above shall be type-approved pursuant to the provisions laid down in:

— Annex 3 to this Regulation for accessories mentioned in paragraphs 6.3.1., 6.3.2., 6.3.3. and 6.3.6.,

— Annex 4 to this Regulation for accessories mentioned in paragraph 6.3.4.,

— Annex 7 to this Regulation for accessories mentioned in paragraph 6.3.5.

6.4.-6.14.   Provisions regarding other components

The other components, which are shown in Table 1, shall be type approved pursuant to the provisions laid down in the annexes which can be determined from the table.

Table 1

6.15.   General design rules regarding components

Provisions regarding the 80 per cent stop valve

6.15.1.1.   The connection between the float and the closing unit of the 80 per cent stop valve shall not be deformed under normal conditions of use.

6.15.1.2.   If the 80 per cent stop valve of the container comprises a float, the latter shall withstand an outside pressure of 4 500 kPa.

6.15.1.3.   The closing unit of the device that limits the filling at 80 per cent +0/-5 per cent of the capacity of the container, for which the 80 per cent stop valve is designed, shall withstand a pressure of 6 750 kPa. At the cut-off position, the filling rate at a differential pressure of 700 kPa shall not exceed 500 cm

3

/minute. The valve must be tested with all the containers on which it is intended to be fitted or the manufacturer must declare by calculation for which container types this valve is suitable.

6.15.1.4.   When the 80 per cent stop valve does not comprise any float, it shall not be possible to continue filling, after closing-off, at a rate exceeding 500 cm

3

/minute.

6.15.1.5.   The device shall bear a permanent marking, indicating the container-type for which it has been designed, diameter and angle, and if applicable mounting indication.

Electrical operated devices containing LPG shall, in order to prevent in case of fracture of the component electric sparks on the surface of fracture:

(i) be insulated in a manner that no current is lead through LPG containing parts

(ii) have the electrical system of the device isolated:

— from the body

— from the container for the fuel pump.

Isolation resistance shall be > 10 MΩ.

6.15.2.1.   The electrical connections inside the boot and passengers compartment shall comply with insulation class IP 40 according to IEC 529.

6.15.2.2   All other electrical connections shall comply with insulation class IP 54 according to IEC 529.

6.15.2.3.   The power supply bushing (fuel pump/actuators/fuel level sensor) to establish an isolated and tight electrical connection shall be of a hermetic sealed type.

Specific provisions on valves activated by an electric/external (hydraulic, pneumatic) power

6.15.3.1.   In the case of valves activated by an electric/external power (e.g. 80 per cent stop valve, service valve, shut-off valves, non return valves, gas tube pressure relief valve, service coupling), those valves shall be in ‘closed’ position when their power is switched off.

6.15.3.2.   The power of the fuel pump shall be switched off when the electronic control unit becomes defective or loses power.

Heat exchange medium (compatibility and pressure requirements)

6.15.4.1.   The materials constituting a device which are in contact with the heat exchange medium of a device when operating shall be compatible with that fluid and shall be designed to withstand a pressure of 200 kPa of the heat exchange medium. The material shall meet the prescriptions laid down in Annex 15, paragraph 17.

6.15.4.2.   The compartment containing the heat exchange medium of the vaporizer/pressure regulator shall be leak proof at a pressure of 200 kPa.

6.15.5.   A component consisting of both high pressure and low pressure parts shall be so designed to prevent a pressure build up in the low pressure part above 2,25 times the maximum working pressure for which it has been tested. Components connected directly to the tank pressure shall be designed for the classification pressure of 3 000 kPa. Venting to the motor compartment or outside of the vehicle is not allowed.

Specific provisions to prevent any gas flow

6.15.6.1.   The pump shall be so designed that the outlet pressure never exceeds 3 000 kPa, when there is e.g. blocking of the tubing or not opening of a shut-off valve. This can be realized by switching off the pump or by recirculating to the container.

6.15.6.2.   The pressure regulator/vaporizer shall be so designed as to prevent any gas flow when the regulator/vaporizer unit is supplied with LPG at a pressure ≤ 4 500 kPa when the regulator is not operating.

6.15.7.   Provisions regarding the gas tube relief valve

6.15.7.1.   The gas-tube pressure relief valve shall be so designed as to open at a pressure of 3 200 ± 100 kPa.

6.15.7.2.   The gas-tube pressure relief valve shall not have internal leakage up to 3 000 kPa.

Provisions regarding the pressure relief valve (discharge valve)

6.15.8.1.   The pressure relief valve shall be mounted inside the container or on the container, in the area where the fuel is in gaseous state.

6.15.8.2.   The pressure relief valve shall be so designed as to open at a pressure of 2 700 ± 100 kPa.

6.15.8.3.   The flow capacity of the pressure relief valve, determined with compressed air at a pressure which is 20 per cent higher than the normal operating-pressure must be at least

Q ≥ 10,66 · A

0,82

in which:

Q

=

flow of air in standard m

3

/min (100 kPa absolute and temperature of 15 °C)

A

=

exterior surface of the container in m

2

.

The flow test results must be corrected to standard conditions:

air pressure of 100 kPa absolute and temperature of 15 °C.

When the pressure relief valve is considered as a pressure relief device, the flow shall be at least 17,7 standard m

3

/min.

6.15.8.4.   The pressure relief valve shall not have internal leakage up to 2 600 kPa.

6.15.8.5.   The pressure relief device (fuse) shall be designed to open at a temperature of 120 ± 10 °C.

6.15.8.6.   The pressure relief device (fuse) shall be designed to have, when opened, a flow capacity of:

Q ≥ 2,73 · A

in which:

Q

=

flow of air in standard m

3

/min (100 kPa absolute and temperature of 15 °C)

A

=

exterior surface of the container in m

2

.

The flow test must be carried out at an upstream air pressure of 200 kPa absolute, and at temperature of 15 °C.

The flow test results must be corrected to standard conditions:

air pressure of 100 kPa absolute, and temperature of 15 °C.

6.15.8.7.   The pressure relief device shall be mounted on the container in the gaseous zone.

6.15.8.8.   The pressure relief device shall be fitted to the container in such a manner that it can discharge into the gas tight housing, when its presence is prescribed.

6.15.8.9.   The pressure relief device (fuse) shall be tested according to the provisions described in Annex 3, paragraph 7.

6.15.9.   Power dissipation of the fuel pump

At minimum fuel level whereby the engine is still operating the heat build-up by the fuel pump(s) should never cause the pressure relief valve to open.

Provisions regarding the filling unit

6.15.10.1.   The filling unit shall be equipped with at least one soft-seated non-return valve, and it shall not be dismountable by design.

6.15.10.2.   The filling unit shall be protected against contamination.

6.15.10.3.   The design and dimensions of the connecting area of the filling unit must comply with those in the figures in Annex 9.

The filling unit shown in Figure 5 is only applicable for motor vehicles of categories M

2

, M

3

, N

2

, N

3

and M

1

having a maximum total mass > 3 500 kg(6).

6.15.10.4.   The filling unit shown in Figure 4 may also apply for motor vehicles of categories M

2

, M

3

, N

2

, N

3

and M

1

having a maximum total mass > 3 500 kg(6).

6.15.10.5.   The outside filling unit is connected to the container by a hose or pipe.

Specific provisions regarding the light vehicle Euro filling unit (Annex 9 — Figure 3):

6.15.10.6.1.   The dead volume between the front sealing surface and the front of the non-return valve shall not exceed 0,1 cm

3

;

6.15.10.6.2.   The flow through the connector at a pressure difference of 30 kPa shall be at least 60 litres/min, if tested with water.

Specific provisions regarding the heavy-duty vehicle Euro filling unit (Annex 9 — Figure 5):

6.15.10.7.1.   The dead volume between the front sealing surface and the front of the non-return valve shall not exceed 0,5 cm

3

;

6.15.10.7.2.   The flow through the filling unit, with the non-return valve mechanically opened, at a pressure difference of 50 kPa shall be at least 200 litres/min, when tested with water.

6.15.10.7.3.   The Euro filling unit shall comply with the impact test as described in Annex 9, paragraph 7.4.

Provisions regarding the level indicator

6.15.11.1.   The device to verify the level of liquid in the container shall be of an indirect type (for example magnetic) between the inside and outside of the container. If the device to verify the level of liquid in the container is of a direct type, the electric power connections should meet IP54 specifications according to IEC EN 60529:1997-06.

6.15.11.2.   If the level indicator of the container comprises a float, the latter shall withstand an outside pressure of 3 000 kPa.

Provisions regarding the gas tight housing of the container.

6.15.12.1.   The gas-tight housing outlet shall have a total free-cross-section of at least 450 mm

2

.

6.15.12.2.   The gas-tight housing shall be leak-proof at a pressure of 10 kPa with the aperture(s) closed off, maximum allowed leak rate of 100 cm

3

/h vapour and show no permanent deformation.

6.15.12.3.   The gas-tight housing shall be designed to withstand a pressure of 50 kPa.

Provisions regarding the remotely controlled service valve with excess flow valve.

Provisions regarding the service valve

6.15.13.1.1.   In case the service valve is combined with a LPG fuel supply pump, identification of the pump must be realised by the marking ‘PUMP INSIDE’ and the identification of the pump either on the marking plate of the LPG container or on the multivalve if present. Electrical connections inside the LPG container shall comply with insulation class IP 40 according to IEC 529.

6.15.13.1.2.   The service valve shall withstand a pressure of 6 750 kPa in the open and closed position.

6.15.13.1.3.   The service valve shall not, at the shut-off position, allow an internal leak rate in the flow direction. There may be leak in the back flow direction.

Provisions regarding the excess flow valve

6.15.13.2.1.   The excess flow valve shall be mounted inside the container.

6.15.13.2.2.   The excess flow valve shall be designed with a bypass to allow for equalization of pressures.

6.15.13.2.3.   The excess flow valve shall cut off at a pressure difference over the valve of 90 kPa. At this pressure difference the flow shall not exceed 8 000 cm

3

/min.

6.15.13.2.4.   When the excess flow valve is at cut-off position, the flow through the by-pass shall not exceed 500 cm

3

/min. at a differential pressure of 700 kPa.

7.   MODIFICATIONS OF A TYPE OF LPG EQUIPMENT AND EXTENSION OF APPROVAL

Every modification of a type of LPG equipment shall be notified to the administrative department which granted the type approval. The department may then either:

7.1.1.   consider that the modifications made are unlikely to have an appreciable adverse effect, and that the equipment still complies with the requirements; or

7.1.2.   consider whether retesting will be partial or complete.

7.2.   Confirmation or refusal of approval, specifying the alterations, shall be communicated by the procedure specified in paragraph 5.3. above to the Parties to the Agreement which apply this Regulation.

7.3.   The competent authority issuing the extension of approval shall assign a series number to each communication form drawn up for such an extension.

8.   (Not allocated)

9.   CONFORMITY OF PRODUCTION

The conformity of production procedures shall comply with those set out in the Agreement, Appendix 2 (E/ECE/324-E/ECE/TRANS/505/Rev.2), with the following requirements:

9.1.   All equipment approved under this Regulation shall be so manufactured as to conform to the type approved by meeting the requirements of paragraph 6. above.

9.2.   In order to verify that the requirements of paragraph 9.1. are met, suitable controls of production shall be carried out.

9.3.   The minimum requirements for conformity of production control tests set forth in Annexes 8, 10 and 15 of this Regulation shall be complied with.

9.4.   The authority which has granted type approval may at any time verify the conformity control methods applied in each production facility. The normal frequency of these verifications shall be once every year.

9.5.   Moreover, each container shall be tested at a minimum pressure of 3 000 kPa in conformity with the prescriptions of paragraph 2.3. of Annex 10 to this Regulation.

9.6.   Every hose assembly which is applied in the high pressure class (Class 1) according to the classification as prescribed in paragraph 2. of this Regulation, shall, during half a minute, be subjected to a test with gas under a pressure of 3 000 kPa.

9.7.   For welded containers at least 1 per 200 containers and one of the remaining number has to be subjected to the radiographic examination according to Annex 10, paragraph 2.4.1.

9.8.   During production 1 of 200 containers and 1 of the remaining number has to be subjected to the above-mentioned mechanical tests as described in Annex 10, paragraph 2.1.2.

10.   PENALTIES FOR NON-CONFORMITY OF PRODUCTION

10.1.   The approval granted in respect of a type of equipment pursuant to this Regulation may be withdrawn if the requirements laid down in paragraph 9. above are not complied with.

10.2.   If a Party to the Agreement applying this Regulation withdraws an approval it has previously granted, it shall forthwith so notify the other Contracting Parties applying this Regulation, by means of a communication form conforming to the model in Annex 2B to this Regulation.

11.   TRANSITIONAL PROVISIONS REGARDING THE VARIOUS COMPONENTS OF THE LPG EQUIPMENT

11.1.   As from the official date of entry into force of the 01 series of amendments to this Regulation, no Contracting Party applying this Regulation shall refuse to grant ECE approval under this Regulation as amended by the 01 series of amendments.

11.2.   As from 3 months after the official date of entry into force of the 01 series of amendments to this Regulation, Contracting Parties applying this Regulation shall grant ECE approvals only if the type of component to be approved meets the requirements of this Regulation as amended by the 01 series of amendments.

11.3.   No Contracting Party applying this Regulation shall refuse a type of component approved to the 01 series of amendments to this Regulation.

11.4.   Until 12 months after the date of entry into force of the 01 series of amendments to this Regulation, no Contracting Party applying this Regulation shall refuse a type of component approved to this Regulation in its original form.

11.5.   Upon the expiration of a period of 12 months after the date of entry into force of the 01 series of amendments, Contracting Parties applying this Regulation may refuse the sale of a type of component which does not meet the requirements of the 01 series of amendments to this Regulation, unless the component is intended as a replacement for fitting on vehicles in use.

12.   PRODUCTION DEFINITELY DISCONTINUED

If the holder of the approval completely ceases to manufacture a type of equipment approved in accordance with this Regulation, he shall so inform the authority which granted the approval. Upon receiving the relevant communication, that authority shall inform thereof the other Parties to the Agreement applying this Regulation by means of a communication form conforming to the model in Annex 2B to this Regulation.

13.   NAMES AND ADDRESSES OF TECHNICAL SERVICES RESPONSIBLE FOR CONDUCTING APPROVAL TESTS, AND OF ADMINISTRATIVE DEPARTMENTS

The Parties to the Agreement applying this Regulation shall communicate to the United Nations Secretariat the names and addresses of the technical services responsible for conducting approval tests and of the administrative departments which grant approval and to which forms certifying approval or extension or refusal or withdrawal of approval, issued in other countries, are to be sent.

PART II

APPROVAL OF A VEHICLE FITTED WITH SPECIFIC EQUIPMENT FOR THE USE OF LIQUIFIED PETROLEUM GASES IN ITS PROPULSION SYSTEM WITH REGARD TO THE INSTALLATION OF SUCH EQUIPMENT

14.   DEFINITIONS

For the purposes of Part II of this Regulation:

14.1.1.   ‘Approval of a vehicle’ means the approval of a vehicle type with regard to the installation of its specific equipment for the use of liquefied petroleum gases in its propulsion system;

‘Vehicle type’ means a vehicle or a family of vehicles fitted with specific equipment for the use of LPG in its propulsion system, which do not differ with respect to the following conditions:

14.1.2.1.   the manufacturer;

14.1.2.2.   the type designation established by the manufacturer;

the essential aspects of design and construction;

14.1.2.3.1.   chassis/floor pan (obvious and fundamental differences);

14.1.2.3.2.   installation of the LPG equipment (obvious and fundamental differences).

15.   APPLICATION FOR APPROVAL

15.1.   The application for approval of a vehicle type with regard to the installation of specific equipment for the use of liquefied petroleum gases in its propulsion system shall be submitted by the vehicle manufacturer or by his duly accredited representative.

15.2.   It shall be accompanied by the undermentioned documents in triplicate: description of the vehicle comprising all the relevant particulars referred to in Annex 1 to this Regulation.

15.3.   A vehicle representative of the vehicle type to be approved, shall be submitted to the technical service conducting the approval tests.

16.   APPROVAL

16.1.   If the vehicle submitted for approval pursuant to this Regulation is provided with all the necessary specific equipment for the use of liquefied petroleum gases in its propulsion system and meets the requirements of paragraph 17. below, approval of that vehicle type shall be granted.

16.2.   An approval number shall be assigned to each type of vehicle approved. Its first two digits shall indicate the series of amendments incorporating the most recent major technical amendments made to the Regulation at the time of issue of the approval.

16.3.   Notice of approval or of refusal or of extension of approval of an LPG vehicle type pursuant to this Regulation shall be communicated to the Parties to the Agreement applying this Regulation, by means of a form conforming to the model in Annex 2D to this Regulation.

There shall be affixed, conspicuously and in a readily accessible space specified on the approval form referred to in paragraph 16.3. above, to every vehicle type approved under this Regulation an international approval mark consisting of:

16.4.1.   A circle surrounding the letter ‘E’ followed by the distinguishing number of the country which has granted approval(7).

16.4.2.   The number of this Regulation, followed by the letter ‘R’, a dash and the approval number to the right of the circle prescribed in paragraph 16.4.1.

16.5.   If the vehicle conforms to a vehicle approved, under one or more other Regulations annexed to the Agreement, in the country which has granted approval under this Regulation, the symbol prescribed in paragraph 16.4.1. need not be repeated; in such case, the Regulation and approval numbers and the additional symbols of all the Regulations under which approval has been granted in the country which has granted approval under this Regulation shall be placed in vertical columns to the right of the symbol prescribed in paragraph 16.4.1.

16.6.   The approval mark shall be clearly legible and be indelible.

16.7.   The approval mark shall be placed close to or on the vehicle data plate.

16.8.   Annex 2C to this Regulation gives examples of the arrangement of the aforesaid approval mark.

17.   REQUIREMENTS FOR THE INSTALLATION OF SPECIFIC EQUIPMENT FOR THE USE OF LIQUEFIED PETROLEUM GASES IN THE PROPULSION SYSTEM OF A VEHICLE

17.1.   General

17.1.1.   The LPG equipment as installed in the vehicle shall function in such a manner that the maximum operating pressure for which it has been designed and approved cannot be exceeded.

17.1.2.   All parts of the system shall be type approved for individual parts pursuant to Part I of this Regulation.

17.1.3.   The materials used in the system shall be suitable for use with LPG.

17.1.4.   All parts of the system shall be fastened in a proper way.

17.1.5.   The LPG-system shall show no leaks.

17.1.6.   The LPG-system shall be installed such that is has the best possible protection against damage, such as damage due to moving vehicle components, collision, grit or due to the loading or unloading of the vehicle or the shifting of those loads.

No appliances shall be connected to the LPG-system other than those strictly required for the proper operation of the engine of the motor vehicle.

17.1.7.1.   Notwithstanding the provisions of paragraph 17.1.7., motor vehicles of categories M

2

, M

3

, N

2

, N

3

and M

1

having a maximum total mass > 3 500 kg may be fitted with a heating system to heat the passenger compartment which is connected to the LPG-system.

17.1.7.2.   The heating system referred to in paragraph 17.1.7.1. shall be permitted if, in the view of the technical services responsible for conducting type approval, the heating system is adequately protected and the required operation of the normal LPG-system is not affected.

17.1.7.3.   Notwithstanding the provisions of paragraph 17.1.7., a mono-fuel vehicle without limp-home system may be equipped with a service coupling in the LPG-system.

17.1.7.4.   The service coupling referred to in paragraph 17.1.7.3. shall be permitted if, in the view of the technical services responsible for conducting type approval, the service coupling is adequately protected and the required operation of the normal LPG-system is not affected. The service coupling must be combined with a separate gas-tight non-return valve whereby it is only possible to operate the engine.

17.1.7.5.   Mono-fuel vehicles installed with a service coupling shall carry a sticker near the service coupling as specified in Annex 17.

Identification of LPG-fuelled M

2

and M

3

category vehicles.

17.1.8.1.   Vehicles of category M

2

and M

3

shall carry a plate as specified in Annex 16.

17.1.8.2.   The plate shall be installed on the front and rear of the M

2

or M

3

category vehicle and on the outside of the doors on the left-hand side for the right hand drive vehicles and on the right-hand side for the left hand drive vehicles.

17.2.   Further requirements

17.2.1.   No component of the LPG-system, including any protective materials which form part of such components, shall project beyond the external surface of the vehicle, with the exception of the filling unit if this does not project more than 10 mm beyond the nominal line of the body panel.

17.2.2.   With the exception of the LPG fuel container, in no cross section of the vehicle any component of the LPG-system, including any protective material which forms part of such components, may extend beyond the lower edge of the vehicle unless another part of the vehicle, within a radius of 150 mm is situated lower.

17.2.3.   No component of the LPG-system shall be located within 100 mm of the exhaust or similar heat source, unless such components are adequately shielded against heat.

17.3   The LPG-system

17.3.1.   An LPG-system shall contain at least the following components:

17.3.1.1.   fuel container;

17.3.1.2.   80 per cent stop valve;

17.3.1.3.   level indicator;

17.3.1.4.   pressure relief valve;

17.3.1.5.   remotely controlled service valve with excess flow valve;

17.3.1.6.   pressure regulator and vaporizer, which may be combined;

17.3.1.7.   remotely controlled shut-off valve;

17.3.1.8.   filling unit;

17.3.1.9.   gas tubes and hoses;

17.3.1.10.   gas-carrying connections between the LPG-system components;

17.3.1.11.   injector or gas injection device or gas mixing piece;

17.3.1.12.   electronic control unit;

17.3.1.13.   pressure relief device (fuse).

17.3.2.   The system may also include the following components:

17.3.2.1.   gas-tight housing, covering the accessories fitted to the fuel container;

17.3.2.2.   non-return valve;

17.3.2.3.   gas tube pressure relief valve;

17.3.2.4.   gas dosage unit;

17.3.2.5.   LPG filter unit;

17.3.2.6.   pressure or temperature sensor;

17.3.2.7.   LPG fuel pump;

17.3.2.8.   power supply bushing for the container (actuators/fuel pump/fuel level sensor);

17.3.2.9.   service coupling (mono-fuel vehicles only & no limp-home system);

17.3.2.10.   fuel selection system and electrical system;

17.3.2.11.   fuel rail.

17.3.3.   The container fittings referred to in paragraphs 17.3.1.2. to 17.3.1.5. may be combined.

17.3.4.   The remotely controlled shut-off valve referred to in paragraph 17.3.1.7. may be combined with the pressure regulator/vaporizer.

17.3.5.   Additional components required for the effective operation of the engine may be installed in that part of the LPG-system where the pressure is less than 20 kPa.

17.4.   Installation of the fuel container

17.4.1.   The fuel container shall be permanently installed in the vehicle and shall not be installed in the engine compartment.

17.4.2.   The fuel container shall be installed in the correct position, according to the instructions from the container manufacturer.

17.4.3.   The fuel container shall be installed such that there is no metal to metal contact, other than at the permanent fixing points of the container.

17.4.4.   The fuel container shall have permanent fixing points to secure it to the motor vehicle or the container shall be secured to the motor vehicle by a container frame and container straps.

When the vehicle is ready for use the fuel container shall not be less than 200 mm above the road surface.

17.4.5.1.   The provisions of paragraph 17.4.5. shall not apply if the container is adequately protected, at the front and the sides and no part of the container is located lower than this protective structure.

17.4.6.   The fuel container(s) must be mounted and fixed so that the following accelerations can be absorbed (without damage occurring) when the containers are full:

Vehicles of categories M

1

and N

1

:

(a) 20 g in the direction of travel

(b) 8 g horizontally perpendicular to the direction of travel

Vehicles of categories M

2

and N

2

:

(a) 10 g in the direction of travel

(b) 5 g horizontally perpendicular to the direction of travel

Vehicles of categories M

3

and N

3

:

(a) 6,6 g in the direction of travel

(b) 5 g horizontally perpendicular to the direction of travel

A calculation method can be used instead of practical testing if its equivalence can be demonstrated by the applicant for approval to the satisfaction of the technical service.

17.5.   Further requirements to the fuel container

17.5.1.   If more than one LPG container is connected to a single delivery tube each container shall be fitted with a non-return valve installed downstream of the remotely controlled service valve and a tube pressure relief valve shall be installed in the delivery tube, downstream of the non-return valve. An adequate filter system has to be placed upstream of the non-return valve(s) to prevent fouling of the non-return valve(s).

17.5.2.   A non-return valve and tube pressure relief valve shall not be required if the backflow pressure of the remotely controlled service valve in the closed position exceeds 500 kPa.

In that case the control of the remotely controlled service valves shall be constructed such that it is impossible for more than one remotely controlled valve to be open at any time. The overlap time to allow switching is limited to two minutes.

17.6.   Accessories to the fuel container

17.6.1.   Remotely controlled service valve with excess flow valve on the container

17.6.1.1.   The remotely controlled service valve with excess flow valve shall be installed directly on the fuel container, without any intervening fittings.

17.6.1.2.   The remotely controlled service valve with excess flow valve shall be controlled such that it is automatically closed when the engine is not running, irrespective of the position of the ignition switch, and shall remain closed as long as the engine is not running.

17.6.2.   Spring-loaded pressure relief valve in the container

17.6.2.1.   The spring-loaded pressure relief valve shall be installed in the fuel container in such a manner that it is connected to the vapour space and can discharge to the surrounding atmosphere. The spring-loaded pressure relief valve may discharge into the gas-tight housing if that gas-tight housing fulfils the requirements of paragraph 17.6.5.

17.6.3.   80 per cent stop valve

17.6.3.1.   The automatic filling level limiter shall be suitable for the fuel container it is fitted to and shall be installed in the appropriate position to ensure that the container cannot be filled to more than 80 per cent.

17.6.4.   Level indicator

17.6.4.1.   The level indicator shall be suitable for the fuel container it is fitted to and shall be installed in the appropriate position.

17.6.5.   Gas-tight housing on the container

17.6.5.1.   A gas-tight housing over the container fittings, which fulfils the requirements of paragraphs 17.6.5.2. to 17.6.5.5. shall be fitted to the fuel container, unless the container is installed outside the vehicle and the container fittings are protected against dirt and water.

17.6.5.2.   The gas-tight housing shall be in open connection with the atmosphere, where necessary through a connecting hose and a lead-through.

17.6.5.3.   The ventilation opening of the gas-tight housing shall point downwards at the point of exit from the motor vehicle. However, it shall not discharge into a wheel arch, nor shall it be aimed at a heat source such as the exhaust.

17.6.5.4.   Any connecting hose and lead-through in the bottom of the bodywork of the motor vehicle for ventilation of the gas-tight housing shall have a minimum clear opening of 450 mm

2

. If a gas tube, other tube or any electrical wiring is installed in the connecting hose and lead-through, the clear opening shall also be at least 450 mm

2

.

17.6.5.5.   The gas-tight housing and connecting hoses shall be gas-tight at a pressure of 10 kPa with the apertures closed off, and show no permanent deformation, with a maximum allowed leak rate of 100 cm

3

/h.

17.6.5.6.   The connecting hose shall be secured in a proper way to the gas-tight housing and the lead-through to ensure that a gas-tight joint is formed.

17.7.   Gas tubes and gas hoses

17.7.1.   Gas tubes shall be made of seamless material: either copper or stainless steel or steel with corrosion-resistant coating.

17.7.2.   If seamless copper is used the tube shall be protected by a rubber or plastic sleeve.

17.7.3.   The outer diameter of gas tubes made of copper shall not exceed 12 mm with a wall thickness of at least 0,8 mm, gas tubes from steel and stainless steel shall not exceed 25 mm with, for gas services, an appropriate wall thickness.

17.7.4.   The gas tube may be made of a non-metallic material if the tube fulfils the requirements of this Regulation, paragraph 6.7.

17.7.5.   The gas tube may be replaced by a gas hose if this hose fulfils the requirement of this Regulation, paragraph 6.7.

17.7.6.   Gas tubes, other than non-metallic gas tubes, shall be secured such that they shall not be subjected to vibration or stresses.

17.7.7.   Gas hoses and non-metallic gas tubes shall be secured such that they shall not be subjected to stresses.

17.7.8.   At the fixing point the gas tube or hose shall be fitted with a protective material.

17.7.9.   Gas tubes or hoses shall not be located at jacking points.

17.7.10.   At passages the gas tubes or hoses, whether or not fitted with a protective sleeve, shall be fitted with protective material.

17.8.   Gas connections between the components of the LPG-system

17.8.1.   Soldered or welded joints and bite-type compression joints are not permitted.

17.8.2.   Gas tubes shall only be connected by compatible fittings with regard to corrosion.

17.8.3.   Stainless steel tubes shall only be joined by stainless steel fittings.

17.8.4.   Distributing-blocks shall be made of corrosion-resistant material.

17.8.5.   Gas tubes shall be connected by appropriate joints, for example, two-part compression joints in steel tubes and joints with olives tapered on both sides or two flanges in copper tubes. Gas tubes shall be connected with appropriate connections. Under no circumstances couplings may be used whereby the tube will be damaged. The burst pressure of the mounted couplings shall be the same or higher as specified for the tube.

17.8.6.   The number of joints shall be limited to a minimum.

17.8.7.   Any joints shall be made in locations where access is possible for inspection.

In a passenger compartment or enclosed luggage compartment the gas tube or hose shall be no longer than reasonably required; this provision is fulfilled when the gas tube or hose does not extend further than from the fuel container to the side of vehicle.

17.8.8.1.   There shall be no gas-conveying connections in the passenger compartment or enclosed luggage compartment with the exception of:

(i) the connections on the gas-tight housing; and

(ii) the connection between the gas tube or hose and the filling unit if this connection is fitted with a sleeve which is resistant against LPG and any leaking gas will be discharged directly into the atmosphere.

17.8.8.2.   The provisions of paragraph 17.8.8. and paragraph 17.8.8.1. shall not apply for M

2

or M

3

category vehicles if the gas tubes or hoses and connections are fitted with a sleeve which is resistant against LPG and which has an open connection to the atmosphere. The open end of the sleeve or ducting shall be situated at the lowest point.

17.9.   Remotely controlled shut-off valve

17.9.1.   A remotely controlled shut-off valve shall be installed in the gas tube from the LPG container to the pressure regulator/vaporizer, as close as possible to the pressure regulator/vaporizer.

17.9.2.   The remotely controlled shut-off valve may be incorporated into the pressure regulator/vaporizer.

17.9.3.   Notwithstanding the provisions of paragraph 17.9.1., the remotely controlled shut-off valve may be installed at a location in the engine bay specified by the manufacturer of the LPG-system if a fuel return system is provided between the pressure regulator and the LPG container.

17.9.4.   The remotely controlled shut-off valve shall be installed such that the fuel supply is cut off when the engine is not running or, if the vehicle is also equipped with another fuel system, when the other fuel is selected. A delay of 2 seconds is permitted for diagnostic purposes.

17.10.   Filling unit

17.10.1.   The filling unit shall be secured against rotation and shall be protected against dirt and water.

17.10.2.   When the LPG container is installed in the passenger compartment or an enclosed (luggage) compartment, the filling unit shall be located at the outside of the vehicle.

17.11.   Fuel selection system and electrical installation

The electrical components of the LPG-system shall be protected against overloads and at least one separate fuse shall be provided in the supply cable.

17.11.1.1.   The fuse shall be installed in a known location where it can be reached without the use of tools.

17.11.2.   The electrical power to LPG-system components which also carry gas may not be conducted by a gas tube.

17.11.3.   All electrical components installed in a part of the LPG-system where the pressure exceeds 20 kPa shall be connected and insulated in a manner that no current is led through LPG containing parts.

17.11.4.   Electrical cables shall be adequately protected against damage. The electrical connections inside the boot and passengers compartment shall comply with insulation class IP 40 according to IEC 529. All other electrical connections shall comply with insulation class IP 54 according to IEC 529.

17.11.5.   Vehicles with more than one fuel system shall have a fuel selection system to ensure that no more than one fuel is supplied to the engine at any time. A short overlap time to allow switching-over is allowed.

17.11.6.   Notwithstanding the provisions of paragraph 17.11.5. in the case of pilot operated dual fuel engines, it is permitted to supply more than one fuel.

17.11.7.   The electrical connections and components in the gas-tight housing shall be constructed such that no sparks are generated.

17.12.   Pressure relief device

17.12.1.   The pressure relief device shall be fitted to the fuel container(s) in such a manner that it can discharge into the gas tight housing, when its presence is prescribed, if that gas tight housing fulfils the requirements of paragraph 17.6.5.

18.   CONFORMITY OF PRODUCTION

The conformity of production procedures shall comply with those set out in the Agreement, Appendix 2 (E/ECE/324-E/ECE/TRANS/505/Rev.2) with the following requirements:

18.1.   All vehicles approved under this Regulation shall be so manufactured as to conform to the type approved by meeting the requirements of paragraph 17. above.

18.2.   In order to verify that the requirements of paragraph 18.1. are met, suitable controls of the production shall be carried out.

18.3.   The authority which has granted type approval may at any time verify the conformity control methods applied in each production facility. The normal frequency of these verifications shall be once every year.

19.   PENALTIES FOR NON-CONFORMITY OF PRODUCTION

19.1.   The approval granted in respect of a type of vehicle pursuant to this Regulation may be withdrawn if the requirements laid down in paragraph 18. above are not complied with.

19.2.   If a Party to the Agreement applying this Regulation withdraws an approval it has previously granted, it shall forthwith so notify the other Contracting Parties applying this Regulation, by means of a communication form conforming to the model in Annex 2D to this Regulation.

20.   MODIFICATION AND EXTENSION OF APPROVAL OF A VEHICLE TYPE

Every modification of the installation of the specific equipment for the use of liquefied petroleum gases in the propulsion system of the vehicle shall be notified to the administrative department which approved the vehicle type. The department may then either:

20.1.1.   Consider that the modifications made are unlikely to have an appreciably adverse effect and that in any case the vehicle still complies with the requirements; or

20.1.2.   Require a further test report from the technical service responsible for conducting the tests.

20.2.   Confirmation or refusal of approval, specifying the alteration, shall be communicated by the procedure specified in paragraph 16.3. above to the Parties to the Agreement applying this Regulation.

20.3.   The competent authority issuing the extension of approval shall assign a series number for such an extension and inform thereof the other Parties to the 1958 Agreement applying this Regulation by means of a communication form conforming to the model in Annex 2D to this Regulation.

21.   PRODUCTION DEFINITELY DISCONTINUED

If the holder of the approval completely ceases to manufacture a type of vehicle approved in accordance with this Regulation, he shall so inform the authority which granted the approval. Upon receiving the relevant communication, that authority shall inform thereof the other Parties to the Agreement applying this Regulation by means of a communication form conforming to the model in Annex 2D to this Regulation.

22.   TRANSITIONAL PROVISIONS REGARDING THE INSTALLATION OF VARIOUS COMPONENTS OF THE LPG EQUIPMENT AND THE TYPE APPROVAL OF A VEHICLE FITTED WITH SPECIFIC EQUIPMENT FOR THE USE OF LIQUEFIED PETROLEUM GAS IN ITS PROPULSION SYSTEM WITH REGARD TO THE INSTALLATION OF SUCH EQUIPMENT

22.1.   As from the official date of entry into force of the 01 series of amendments to this Regulation, no Contracting Party applying this Regulation shall refuse to grant ECE approval under this Regulation as amended by the 01 series of amendments.

22.2.   As from the official date of entry into force of the 01 series of amendments to this Regulation, no Contracting Party applying this Regulation shall prohibit the fitting on a vehicle and the use as first equipment of a component approved under this Regulation as amended by the 01 series of amendments.

22.3.   During the period of 12 months after the date of entry into force of the 01 series of amendments to this Regulation, Contracting Parties applying this Regulation may allow the use of as first equipment of a type of component approved to this Regulation in its original form, when fitted on a vehicle transformed for LPG propulsion.

22.4.   Upon the expiration of a period of 12 months after the date of entry into force of the 01 series of amendments to this Regulation, Contracting Parties applying this Regulation shall prohibit the use as first equipment of a component which does not meet the requirements of this Regulation as amended by the 01 series of amendments, when fitted on a vehicle transformed for LPG propulsion.

22.5.   Upon the expiration of a period of 12 months after the date of entry into force of the 01 series of amendments to this Regulation, Contracting Parties applying this Regulation may refuse first National Registration (first entry into service) of a vehicle which does not meet the requirements of this Regulation as amended by the 01 series of amendments.

23.   NAMES AND ADDRESSES OF TECHNICAL SERVICES RESPONSIBLE FOR CONDUCTING APPROVAL TESTS, AND OF ADMINISTRATIVE DEPARTMENTS

The Parties to the Agreement applying this Regulation shall communicate to the United Nations Secretariat the names and addresses of the technical services responsible for conducting approval tests and of the administrative departments which grant approval and to which forms certifying approval or extension or refusal or withdrawal of approval, issued in other countries, are to be sent.

(1)  As defined in Annex 7 to the Consolidated Resolution on the Construction of Vehicles (R.E.3), (document TRANS/WP.29/78/Rev.1/Amend.2 as last amended by Amend.4).

(2)  1 for Germany, 2 for France, 3 for Italy, 4 for the Netherlands, 5 for Sweden, 6 for Belgium, 7 for Hungary, 8 for the Czech Republic, 9 for Spain, 10 for Serbia, 11 for the United Kingdom, 12 for Austria, 13 for Luxembourg, 14 for Switzerland, 15 (vacant), 16 for Norway, 17 for Finland, 18 for Denmark, 19 for Romania, 20 for Poland, 21 for Portugal, 22 for the Russian Federation, 23 for Greece, 24 for Ireland, 25 for Croatia, 26 for Slovenia, 27 for Slovakia, 28 for Belarus, 29 for Estonia, 30 (vacant), 31 for Bosnia and Herzegovina, 32 for Latvia, 33 (vacant), 34 for Bulgaria, 35 (vacant), 36 for Lithuania, 37 for Turkey, 38 (vacant), 39 for Azerbaijan, 40 for The former Yugoslav Republic of Macedonia, 41 (vacant), 42 for the European Community (Approvals are granted by its Member States using their respective ECE symbol), 43 for Japan, 44 (vacant), 45 for Australia, 46 for Ukraine, 47 for South Africa, 48 for New Zealand, 49 for Cyprus, 50 for Malta 51 for the Republic of Korea, 52 for Malaysia, 53 for Thailand, 54 and 55 (vacant) and 56 for Montenegro. Subsequent numbers shall be assigned to other countries in the chronological order in which they ratify or accede to the Agreement Concerning the Adoption of Uniform Technical Prescriptions for Wheeled Vehicles, Equipment and Parts which can be Fitted and/or be Used on Wheeled Vehicles and the Conditions for Reciprocal Recognition of Approvals Granted on the Basis of these Prescriptions, and the numbers thus assigned shall be communicated by the Secretary-General of the United Nations to the Contracting Parties to the Agreement.

(3)  Either combined or separate

(4)  Only applicable when the gas dosage actuator is not integrated in the gas injection device.

(5)  Applicable only when the operating pressure of the gas mixing piece exceeds 20 kPa (Class 2).

(6)  As defined in the Consolidated Resolution on the Construction of Vehicles (R.E.3), Annex 7 (document TRANS/WP.29/78/Rev.1/Amend.2, as last amended by Amend.4).

(7)  See footnote 2

ANNEX 1

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

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ANNEX 2A

ARRANGEMENT OF THE LPG EQUIPMENT TYPE-APPROVAL MARK

(See paragraph 5.2. of this Regulation)

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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

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Appendix (containers only)

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ANNEX 2C

ARRANGEMENT OF APPROVAL MARKS

MODEL A

(See paragraph 16.2. of this Regulation)

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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)

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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

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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:

a)

One specimen shall be held at a controlled temperature of not less than 90 °C and a pressure not less than test pressure (3 000 kPa) for 24 hours. At the end of this test there shall be no leakage or visible sign of extrusion of any fusible metal used in the design.

b)

One specimen shall be fatigue tested at a pressure cycling rate not to exceed 4 cycles per minute as follows:

i)

held at 82 °C while pressured for 10 000 cycles between 300 and 3 000 kPa;

ii)

held at –20 °C while pressured for 10 000 cycles between 300 and 3 000 kPa.

At the end of this test there shall be no leakage, or any visible sign of extrusion of any fusible metal used in the design.

c)

Exposed brass pressure retaining components of pressure relief device shall withstand, without stress corrosion cracking, a mercurous nitrate test as described in ASTM B154(3). The pressure relief device shall be immersed for 30 minutes in an aqueous mercurous nitrate solution containing 10 g of mercurous nitrate and 10 ml of nitric acid per litre of solution. Following the immersion, the pressure relief device shall be leak tested by applying an aerostatic pressure of 3 000 kPa for one minute during which time the component shall be checked for external leakage. Any leakage shall not exceed 200 cm

3

/h.

d)

Exposed stainless steel pressure retaining components of pressure relief device shall be made of an alloy type resistant to chloride induced stress corrosion cracking.

(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:

Vaporizer

:

see paragraph 2.6. of this Regulation.

Pressure regulator

:

see paragraph 2.7. of this Regulation.

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

Class 1

:

for the part which is in contact with the pressure of the containers.

Class 2

:

for the part which is in contact with the regulated pressure and with a maximum regulated pressure during operation of 450 kPa.

Class 2A

:

for the part which is in contact with the regulated pressure and with a maximum regulated pressure during operation of 120 kPa.

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:

(i) High pressure rubber hoses (Class 1, e.g. Filling hose)

(ii) Low pressure rubber hoses (Class 2)

(iii) High pressure synthetic hoses (Class 1)

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:

(i) medium: n-pentane

(ii) temperature: 23 °C (tolerance acc. to ISO 1817)

(iii) immersion period: 72 hours

Requirements:

(i) maximum change in volume 20 per cent

(ii) maximum change in tensile strength 25 per cent

(iii) maximum change in elongation at break 30 per cent

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:

(i) temperature: 70 °C (test temperature = maximum operating temperature minus 10 °C)

(ii) exposure period: 168 hours

Requirements:

(i) maximum change in tensile strength 25 per cent

(ii) maximum change in elongation at break –30 per cent and +10 per cent

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:

(i) medium: n-hexane

(ii) temperature: 23 °C (tolerance acc. to ISO 1817)

(iii) immersion period: 72 hours

Requirements:

(i) maximum change in volume 30 per cent

(ii) maximum change in tensile strength 35 per cent

(iii) maximum change in elongation at break 35 per cent

1.4.1.2.   

Resistance to ageing according

to ISO 188 with the following conditions:

(i) temperature: 70 °C (test temperature = maximum operating temperature minus 10 °C)

(ii) exposure period: 336 hours

Requirements:

(i) maximum change in tensile strength 25 per cent

(ii) maximum change in elongation at break –30 per cent and +10 per cent

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 cm

3

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)

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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:

(i) medium: n-pentane

(ii) temperature: 23 °C (tolerance acc. to ISO 1817)

(iii) immersion period: 72 hours

Requirements:

(i) maximum change in volume 20 per cent

(ii) maximum change in tensile strength 25 per cent

(iii) maximum change in elongation at break 30 per cent

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:

(i) temperature: 115 °C (test temperature = maximum operating temperature minus 10 °C)

(ii) exposure period: 168 hours

Requirements:

(i) maximum change in tensile strength 25 per cent

(ii) maximum change in elongation at break –30 per cent and +10 per cent

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:

(i) medium: n-hexane

(ii) temperature: 23 °C (tolerance acc. to ISO 1817)

(iii) immersion period: 72 hours

Requirements:

(i) maximum change in volume 30 per cent

(ii) maximum change in tensile strength 35 per cent

(iii) maximum change in elongation at break 35 per cent

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

(i) temperature: 115 °C (test temperature = maximum operating temperature minus 10 °C)

(ii) exposure period: 336 hours

Requirements:

(i) maximum change in tensile strength 25 per cent

(ii) maximum change in elongation at break –30 per cent and +10 per cent

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 cm

3

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)

[Bild bitte in Originalquelle ansehen]

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:

(i) medium: n-pentane

(ii) temperature: 23 °C (tolerance acc. to ISO 1817)

(iii) immersion period: 72 hours

Requirements:

(i) maximum change in volume 20 per cent

(ii) maximum change in tensile strength 25 per cent

(iii) maximum change in elongation at break 30 per cent

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:

(i) temperature: 115 °C (test temperature = maximum operating temperature minus 10 °C)

(ii) exposure period: 336 hours

Requirements:

(i) maximum change in tensile strength 35 per cent

(ii) maximum change in elongation at break –30 per cent and +10 per cent

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:

(i) specimen type: type 1 BA

(ii) tensile speed: 20 mm/min

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

Requirements:

(i) tensile strength not less than 20 MPa

(ii) elongation at break not less than 50 per cent.

3.3.2.2.   

Resistance to n-pentane

according to ISO 1817 with the following conditions:

(i) medium: n-pentane

(ii) temperature: 23 °C (tolerance according to ISO 1817)

(iii) immersion period: 72 hours

Requirements:

(i) maximum change in volume 2 per cent

(ii) maximum change in tensile strength 10 per cent

(iii) maximum change in elongation at break 10 per cent

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:

(i) temperature: 115 °C (test temperature = maximum operating temperature minus 10 °C)

(ii) exposure period: 24 and 336 hours

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:

(i) maximum change in tensile strength 35 per cent after 336 hours ageing compared to the tensile strength of the 24 hours aged material

(ii) maximum change in elongation at break 25 per cent after 336 hours ageing compared to the elongation at break of the 24 hours aged material.

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:

(i) medium: n-hexane

(ii) temperature: 23 °C (tolerance according to ISO 1817)

(iii) immersion period: 72 hours

Requirements:

(i) maximum change in volume 30 per cent

(ii) maximum change in tensile strength 35 per cent

(iii) maximum change in elongation at break 35 per cent

3.4.1.3.   

Resistance to ageing according

to ISO 188 with the following conditions:

(i) temperature: 115 °C (test temperature = maximum operating temperature minus 10 °C)

(ii) exposure period: 336 hours

Requirements:

(i) maximum change in tensile strength 25 per cent

(ii) maximum change in elongation at break –30 per cent and +10 per cent

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:

(i) specimen type: type 1 BA

(ii) tensile speed: 20 mm/min

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

Requirements:

(i) tensile strength not less than 20 MPa

(ii) elongation at break not less than 100 per cent.

3.4.3.2.   

Resistance to n-hexane

according to ISO 1817 with the following conditions:

(i) medium: n-hexane

(ii) temperature: 23 °C (tolerance according to ISO 1817)

(iii) immersion period: 72 hours

Requirements:

(i) maximum change in volume 2 per cent

(ii) maximum change in tensile strength 10 per cent

(iii) maximum change in elongation at break 10 per cent

3.4.3.3.   

Resistance to ageing

according to ISO 188 with the following conditions:

(i) temperature: 115 °C (test temperature = maximum operating temperature minus 10 °C)

(ii) exposure period: 24 and 336 hours

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:

(i) maximum change in tensile strength 20 per cent after 336 hours ageing compared to the tensile strength of the 24 hours aged material

(ii) maximum change in elongation at break 50 per cent after 336 hours ageing compared to the elongation at break of the 24 hours aged material.

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 cm

3

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)

[Bild bitte in Originalquelle ansehen]

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:

— The overpressure test has to be performed on each non-return valve.

— The endurance test shall be carried out with a nozzle specifically intended for the filling unit under test. 6 000 cyles shall be applied according to the following procedure:

— connect the nozzle to the connector and open the filling unit system;

— leave in open situation for at least 3 seconds;

— close the filling unit and disconnect the nozzle.

Figure 1

Connecting area of the Bayonet filling unit

[Bild bitte in Originalquelle ansehen]

Figure 2

Connecting area of the Dish filling unit

[Bild bitte in Originalquelle ansehen]

Figure 3

Connecting area of the light vehicle Euro filling unit

[Bild bitte in Originalquelle ansehen]

Figure 4

Connecting area of the ACME filling unit

[Bild bitte in Originalquelle ansehen]

Figure 5

Connecting area of the heavy-duty vehicle Euro filling unit

[Bild bitte in Originalquelle ansehen]

(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

P

h

=

hydraulic test pressure in kPa;

P

r

=

container bursting pressure measured in the bursting test, in kPa;

R

e

=

minimum yield stress in N/mm

2

guaranteed by the material standard;

R

m

=

minimum tensile strength in N/mm

2

guaranteed by the material standard;

R

mt

=

actual tensile strength, in N/mm

2

;

a

=

calculated minimum thickness of the cylindrical shell wall, in mm;

b

=

calculated minimum thickness of dished ends, in mm;

D

=

nominal outside diameter of the container, in mm;

R

=

inside radius of the dished end of the standard cylindrical container, in mm;

r

=

inside knuckle of the dished end of the standard cylindrical container, in mm;

H

=

outside height of dished part of container end, in mm;

h

=

height of cylindrical part of dished end, in mm;

L

=

length of container's stress-resistant shell, in mm;

A

=

elongation value (per cent) of parent material;

V

0

=

initial volume of the container at the moment when the pressure is increased in the burst test, in dm

3

;

V

=

final volume of the container on bursting, in dm

3

;

g

=

gravity, in m/s

2

;

c

=

shape factor;

Z

=

stress reduction factor.

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:

(a) for metal containers: chemical cast analysis certificates;

(b) for all-composite containers: chemical resistance analysis certificates related to tests performed according to the requirements of Appendix 6;

(c) mechanical properties of the material in respect of the steels or other materials applied for the construction of the parts subject to pressure.

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:

[Bild bitte in Originalquelle ansehen]

1.6.1.1.2.   Containers with longitudinal welds:

[Bild bitte in Originalquelle ansehen]

(i) z = 0,85 where the manufacturer radiographs each weld intersection and 100 m of the adjacent longitudinal weld and 50 mm (25 mm each side of the intersection) of the adjacent circumferential weld.

This test has to be performed per machine at the beginning and end of each work shift period from continuous production.

(ii) z = 1 where each weld intersection and 100 mm of the adjacent longitudinal weld and 50 mm (25 each side of the intersection) of the adjacent circumferential weld is spot radiographed.

This test has to be performed at 10 per cent of the container production: the containers to be tested are chosen randomly. Should these radiograph tests reveal unacceptable defects, as defined in paragraph 2.4.1.4., all the necessary steps must be taken to examine the production run in question and eliminate the defects.

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:

[Bild bitte in Originalquelle ansehen]

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:

[Bild bitte in Originalquelle ansehen]

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:

(a) During production: 1 container from each batch

(b) For type testing, see Table 2

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:

(a) One tensile test on parent material; the test piece to be taken in the longitudinal direction (if this is not possible, it may be taken in a circumferential direction);

(b) One tensile test on parent material of the bottom;

(c) One tensile test perpendicular to the longitudinal weld;

(d) One tensile test perpendicular to the circumferential weld;

(e) One bend test on the longitudinal weld, the inner surface in tension;

(f) One bend test on the longitudinal weld, the outer surface in tension;

(g) One bend test on the circumferential weld, the inner surface in tension;

(h) One bend test on the circumferential weld, the outer surface in tension; and

(i) One macroscopic test of a welded section;

(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 (P

r

) 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:

(a) fill the container to be tested with a non-corrosive fluid such as oil, inhibited water or glycol;

(b) cycle the pressure in the container between not more than 300 kPa and not less than 3 000 kPa at a rate not to exceed 10 cycles per minutes.

This cycle shall be performed at least 10 000 times and continued until 20 000 times unless a leak before break appears;

(c) the number of cycles to failure shall be reported, along with the location and description of the failure initiation.

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:

(a) Fill the container to be tested with a non-corrosive fluid such as oil, inhibited water or glycol;

(b) Condition for 48 hours at 0 kPa, 65 °C, and 95 per cent or greater relative humidity.

(c) Hydrostatically pressurize for 3 600 cycles not exceeding 10 cycles per minute, between not more than 300 kPa and not less than 3 000 kPa at 65 °C and 95 per cent humidity;

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 (T

G

) below the design temperature +50 °C.

2.3.6.6.2.   Test procedure

One finished container shall be tested as follows:

(a) The container shall be pressurized to 3 000 kPa and held at a temperature defined according the table on the basis of the test period duration:

Table 3

Test temperature relating to the High temperature creep test duration

(b) The container shall be submitted to an external leak test.

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 mm

2

.

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 mm

2

.

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:

(a) same type approval owner,

(b) same shape (cylindrical, special shape),

(c) same material,

(d) same or greater wall thickness,

(e) same or smaller diameter (cylindrical container),

(f) same height or smaller height (special container shape),

(g) same or smaller external surface,

(h) same configuration of accessories fitted to the container(2).

2.6.2.   Container set-up

(a) The container shall be placed in the designed position by the manufacturer with the container bottom approximately 100 mm above the fire source.

(b) Shielding shall be used to prevent direct flame impingement on the fusible plug (PRD) if present. The shielding shall not be in direct contact with the fusible plug (PRD).

(c) Any failure during the test of a valve, fitting or tubing that is not part of the intended protection system for the design shall invalidate the result.

(d) Containers with a length of less than 1,65 m: The centre of the container shall be positioned over the centre of the fire source.

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:

(a) The fire temperature just below the container, along the bottom of the container, at minimum two locations, not more than 0,75 m apart;

(b) The wall temperature in the bottom of the container;

(c) The wall temperature within 25 mm from the pressure relief device;

(d) The wall temperature on the top of the container, in the centre of the fire source;

(e) The pressure inside the container.

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 mm

2

. 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

(a) Container shall be filled with 80 per cent in volume of LPG (commercial fuel) and tested in the horizontal position at working pressure;

(b) Immediately following the ignition, the fire shall produce flame impingement on the surface of the container, along 1,65 m length of the fire source across the container;

(c) Within 5 minutes of ignition at least one thermocouple shall indicate the temperature of fire just below the container of at least 590 °C. This temperature shall be maintained for the remaining duration of the test, namely until when no overpressure is present in the container;

(d) The severity of the test conditions shall not be mitigated by ambient conditions (e.g. rain, moderate/high wind etc.).

2.6.6.   Test results:

(a) A burst of the container shall invalidate the test result.

(b) A pressure of more than 3 700 kPa, i.e. 136 per cent of the set pressure of the PRV (2 700 kPa), during the test shall invalidate the test result.

A pressure between 3 000 and 3 700 kPa shall only invalidate the test result in case visible plastic deformation is observed.

(c) In case the behaviour of the protection system does not comply with the specification of the manufacturer and it leads to a mitigating test condition the result shall be invalidated.

(d) For a composite container a release of LPG via the surface is accepted in case of a controlled release. A release of gaseous LPG within 2 minutes after the start of the test or a release capacity of more than 30 litres per minute shall invalidate the test result.

(e) The results shall be presented in a test summary and shall include the following data for each container as a minimum:

— Description of the container configuration.

— Photo of the container set-up and PRD.

— Applied method including time interval between measurements.

— The elapsed time from ignition of the fire to the start of venting of LPG and actual pressure.

— Time to reach atmospheric pressure.

— Pressure and temperature diagrams.

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:

[Bild bitte in Originalquelle ansehen]

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:

— in a horizontal position,

— vertically on each end,

— at an angle of 45°.

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.

(a) If the outer layer has a mechanical (load carrying) function, the container shall be burst tested according to the requirements of paragraph 2.2. of this annex, after exposing to a representative UV-radiation;

(b) If the outer layer has a protective function, the manufacturer has to prove that the coating remains integer within 20 years, in order to protect the under-laying structural layers from a representative UV-radiation.

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.

Appendix 1

Figure 1

Types of main longitudinal butt welds

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Figure 2

Circumferential butt weld

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Figure 3

Examples of welded studded plates

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Figure 4

Examples of welded rings with flange

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Appendix 2

Figure 1

Containers with longitudinal and circumferential welds, Location of test-pieces

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Figure 2a

Containers with circumferential welds only and side-mounted valve blocks; Location of test-pieces

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Figure 2b

Containers with circumferential welds only and valve boss/plate fitted to the end.

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Appendix 3

Figure 1

Illustration of bend test

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Figure 2

Test piece for tensile test perpendicular to the weld

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Appendix 4

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Note:

For torispherical ends

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Relationship between H/D and shape factor C

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Values of shape factor C for H/D between 0,20 and 0,25

Relationship between H/D and shape factor C

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Values of shape factor C for H/D between 0,25 and 0,50

Appendix 5

EXAMPLES OF SPECIAL VESSELS

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Appendix 6

MATERIAL TEST METHODS

Chemical resistance

Materials used in an all-composite container must be tested according to standard ISO 175 for 72 hours at room temperature.

Demonstrating the chemical resistance by using data from literature is also allowed.

Compatibility with the following media shall be checked:

(a) brake fluid;

(b) window cleaner;

(c) cooling liquid;

(d) non-leaded petrol;

(e) solution of deionized water, sodium chloride (2,5 % by mass ±0,1 %), (calcium chloride (2,5 % by mass ±0,1 %) and sulphuric acid sufficient to achieve a solution of pH 4,0 ± 0,2.

Test acceptance criteria:

(a) Elongation:

The elongation of a thermoplastic material, after testing, must be at least 85 per cent of the initial elongation. The elongation of an elastomer, after testing, must be at least larger than 100 per cent.

(b) For structural components (e.g., fibres):

The residual strength for a structural component after testing must be at least 80 per cent of the original tensile strength.

(c) Non-structural components (e.g., coating):

There are no visual cracks allowed.

2.   Composite structure

(a) Fibres embedded in a matrix

(b) Dry fibres on an isotensoid shape

3.   Protective coating

UV-radiation degrades polymeric material when directly subjected to the sunlight. Depending on the installation, the manufacturer has to proof a ‘safe life’ for the coating.

4.   Thermoplastic components

The Vicat softening temperature of a thermoplastic component must be above 70 °C. For structural components, the Vicat softening temperature must be at least 75 °C.

5.   Thermoset components

The Vicat softening temperature of a thermo-set component must be above 70 °C.

6.   Elastomeric components

The glass transition temperature (T

g

) of an elastomer component must be lower than –40 °C. The glass transition temperature shall be tested according ISO 6721 ‘Plastics — Determination of dynamic mechanical properties’. The Tg-onset is derived from the plotted diagram storage modulus versus temperature by determining the temperature, where the two tangents, which are representing the slopes of the diagram before and after the dramatic loss of stiffness, intersects.

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: