SIST EN 12805:2002

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.5H]HUYRDUMLBauteile für Autogasanlagen/Treibgasanlagen - AutogastanksComposants pour véhicules au GPL - RéservoirsAutomotive LPG components - Containers43.060.40Sistemi za gorivoFuel systems23.020.30MHNOHQNHPressure vessels, gas cylindersICS:Ta slovenski standard je istoveten z:EN 12805:2002SIST EN 12805:2002en01-november-2002SIST EN 12805:2002SLOVENSKI
STANDARD



SIST EN 12805:2002



EUROPEAN STANDARDNORME EUROPÉENNEEUROPÄISCHE NORMEN 12805May 2002ICS 23.020.30; 43.060.40English versionAutomotive LPG components - ContainersComposants pour véhicules au GPL - RéservoirsBauteile für Autogasanlagen/Treibgasanlagen -AutogastanksThis European Standard was approved by CEN on 1 March 2002.CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this EuropeanStandard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such nationalstandards may be obtained on application to the Management Centre or to any CEN member.This European Standard exists in three official versions (English, French, German). A version in any other language made by translationunder the responsibility of a CEN member into its own language and notified to the Management Centre has the same status as the officialversions.CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece,Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom.EUROPEAN COMMITTEE FOR STANDARDIZATIONCOMITÉ EUROPÉEN DE NORMALISATIONEUROPÄISCHES KOMITEE FÜR NORMUNGManagement Centre: rue de Stassart, 36
B-1050 Brussels© 2002 CENAll rights of exploitation in any form and by any means reservedworldwide for CEN national Members.Ref. No. EN 12805:2002 ESIST EN 12805:2002



EN 12805:2002 (E)2ContentspageForeword.4Introduction.51Scope.52Normative references.53Terms, definitions, symbols and abbreviations.63.1Terms and definitions.63.2Symbols and abbreviations.74Technical requirements.84.1General provisions.84.2Dimensions.84.3Steel.84.4Design temperature.94.5Design pressure.94.6Heat treatment.94.7Calculation of the parts under pressure.94.7.1Wall thickness of the cylindrical shell.94.7.2Non-cylindrical containers.104.7.3Container ends.105Construction and workmanship.115.1General requirements.115.2Welding requirements.115.2.1Welding qualifications.115.2.2Technical welding requirements.115.2.3Shift rotating of welds.115.2.4Inspection of welds.125.2.5Weld repair.125.3Tolerances.135.3.1Out-of-roundness.135.3.2Straightness.135.3.3Capacity.135.3.4Position.135.4Openings.135.5Accessories.136Markings.147Tests during the production process and on prototypes.157.1Tests to be performed.157.2Destructive testing.157.2.1General requirements.157.2.2Tensile test.167.2.3Retesting for a tensile test.167.2.4Bend test.167.2.5Retesting for a bend test.177.2.6Macroscopic examination.177.3Burst test under hydraulic pressure.177.3.1Test conditions.177.3.2Interpretation of test.177.3.3Test acceptance conditions.177.3.4Retesting for burst test.18SIST EN 12805:2002



EN 12805:2002 (E)37.4Hydraulic test.187.5Hardness test.187.6Fatigue test, only for containers for which the strength can not be calculated.197.7Bonfire test.197.7.1General.197.7.2Container set-up.207.7.3Fire source.207.7.4Temperature and pressure measurements.207.7.5General test requirements.207.7.6Acceptable results.217.8Radiographic examination.21Annex A (informative)
Examples of container shapes.22Annex B (informative)
Examples of container ends.23Annex C (normative)
Examples of butt welds.24Annex D (normative)
Examples of welded plates and rings.25Annex E (normative)
Shift rotating of welds.26Annex F (normative)
Tolerance on position of plate or ring.27Annex G (normative)
Location of test specimen.28G.1Location of test specimen from a 2-section container.28G.2Location of test specimen from a 3-section container.29G.3Location of macrosection for valve boss/plate welds.30Annex H (normative)
Test specimen for mechanical tests.31Annex I (normative)
Radiography of welds.32Annex J (normative)
Determination of the shape factor C.33Key35Annex K (informative)
Type approval requirements.36K.1Application for type approval.36K.2Approval according to UN ECE Regulation 67.36K.3Modification of a container type and extension of approval.37K.4Conformity of production.37K.5Production definitely discontinued.37Annex L (informative)
Approval mark and communication form.38L.1Type approval mark.38L.2Example of a communication form.38L.3International country numbers in accordance with UN-ECE regulation 67.41Bibliography.42SIST EN 12805:2002



EN 12805:2002 (E)4ForewordThis document EN 12805:2002 has been prepared by Technical Committee CEN/TC 286, "Liquefied petroleum gasequipment and accessories", the secretariat of which is held by NSAI.This European Standard shall be given the status of a national standard, either by publication of an identical text orby endorsement, at the latest by November 2002, and conflicting national standards shall be withdrawn at the latestby November 2002.This document has been prepared under a mandate given to CEN by the European Commission and the EuropeanFree Trade Association, and supports essential requirements of EU Directive(s).Annexes A, B, K and L are informative, annexes C to J are normative.According to the CEN/CENELEC Internal Regulations, the national standards organizations of the followingcountries are bound to implement this European Standard: Austria, Belgium, Czech Republic, Denmark, Finland,France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Spain,Sweden, Switzerland and the United Kingdom.SIST EN 12805:2002



EN 12805:2002 (E)5IntroductionThis European Standard defines requirements for the design, manufacturing and testing of welded steel automotiveLiquefied Petroleum Gas (LPG) containers.This European Standard calls for the use of substances and procedures that can be injurious to health if adequateprecautions are not taken. It refers only to technical suitability and does not absolve the user from legal obligationsrelating to health and safety at any stage.It has been assumed in the drafting of this European Standard that execution of its provisions is entrusted toappropriately qualified and experienced people.1 ScopeThis European Standard specifies the requirements for design, manufacturing and testing of welded steelautomotive Liquefied Petroleum Gas (LPG) containers, to be permanently attached to a motor vehicle, where theautomotive LPG is to be used as a fuel in the vehicle.2 Normative referencesThis European Standard incorporates by dated or undated reference, provisions from other publications. Thesenormative references are cited at the appropriate places in the text, and the publications are listed hereafter. Fordated references, subsequent amendments to or revisions of any of these publications apply to this EuropeanStandard only when incorporated in it by amendment or revision. For undated references the latest edition of thepublication referred to applies (including amendments).EN 287-1, Approval testing of welders - Fusion welding – Part 1: Steels.EN 288-3, Specification and approval of welding procedures for metallic materials - Part 3: Welding procedure testsfor the arc welding of steels.EN 589, Automotive fuels - LPG - Requirements and test methods.EN 876, Destructive test on welds in metallic materials - Longitudinal tensile test on weld metal in fusion weldedjoints.EN 895, Destructive tests on welds in metallic materials – Transverse tensile test.EN 910, Destructive tests on welds in metallic materials - Bend tests.EN 1435, Non-destructive examination of welds - Radiographic examination of welded joints.EN 10002-1, Metallic materials - Tensile testing - Part 1: Method of test at ambient temperature.EN 10120, Steel sheet and strip for welded gas cylinders.EN 22768-1, General tolerances - Part 1: Tolerances for linear and angular dimensions without individual toleranceindications (ISO 2768-1:1989).EN ISO 6507-1, Metallic materials - Vickers hardness test - Part 1: Test method (ISO 6507-1:1997).EN ISO 7438, Metallic materials - Bend test (ISO 7438:1985).SIST EN 12805:2002



EN 12805:2002 (E)6EN ISO 7799, Metallic materials - Sheet and strip 3 mm thick or less - Reverse bend test (ISO 7799:1985).ISO 1106-1, Recommended practice for radiographic examination of fusion welded joints - Part 1: Fusion weldedbutt joints in steel plates up to 50 mm thick.ISO 2504, Radiography of welds and vewing conditions for films - Utilization of recommended patterns of imagequality indicators (I.Q.I.).3 Terms, definitions, symbols and abbreviations3.1 Terms and definitionsFor the purposes of this European Standard, the following terms and definitions apply.3.1.1test pressurepressure to which the container is subjected during the test procedure3.1.2design pressurepressure on which the calculations are based3.1.3working pressurepressure under normal operating conditions3.1.4containervessel used for the storage of automotive LPG3.1.5cylindrical containercontainer with a cylindrical shell and two dished ends, either torispherical or elliptical3.1.6special containercontainer other than the cylindrical container3.1.7type of containerscontainer or a group of containers where the individual container does not differ significantly with respect to thefollowing conditions:¾ the manufacturer (different trade names or marks possible);¾ the shape;¾ the openings;¾ the material;¾ the welding process;¾ the heat treatment;¾ the production line;¾ the diameter;SIST EN 12805:2002



EN 12805:2002 (E)7¾ height (in case of a special container);¾ the nominal wall thickness3.1.8stress relievingheat treatment given to objects to reduce the residual stresses without altering the metallurgical structure of steel,by heating to a uniform temperature, Ac1, and cooling in a controlled atmosphere3.1.9normalisingheating to a uniform temperature, Ac3, of the steel and then cooling in a controlled atmosphere3.1.10hot-rolleddeformation of the material at the critical temperature Ac3NOTEAc1 and Ac3 will be obtained from the material data sheet.3.1.11longitudinal weldweld over the full length of the shell or cylindrical part of the shell, excluding welds for fittings3.1.12batchnumber of containers made under the same process, that belong to the same family3.1.13parent materialmaterial in the state before any specific transformation with regards to the container manufacturing process3.1.14Liquefied Petroleum Gas (LPG)mixture of light hydrocarbons, gaseous under normal atmospheric conditions which can be liquefied by increasedpressure or decreased temperature. The main components are propane, propene, butane and butene isomers3.1.15automotive LPGmotor fuel complying with EN 5893.2 Symbols and abbreviationsais the minimum calculated wall thickness of the cylindrical shell in mm,bis the minimum calculated wall thickness of the dished ends in mm,eis the actual wall thickness,Cis the shape factor,Dis the nominal outside diameter of the container in mm,Fis the force in N,gis the gravity in m/s2,his the height of cylindrical part of dished end in mm,His the outside height of dished part of container end in mm,SIST EN 12805:2002



EN 12805:2002 (E)8Pbis the maximum pressure measured in the burst test in kPa,Phis the hydraulic test pressure /design pressure in kPa,ris the inside knuckle radius of the dished end of the standard cylindrical container in mm,Ris the inside dish radius of the dished end of a standard cylindrical container in mm,Reis the minimum yield stress in N/mm2 guaranteed by the material standard,Rmis the minimum tensile strength in N/mm2 guaranteed by the material standard,zis the welding factor,HVis the Vickers hardness,PRVis the pressure relief valve,PRDis the pressure relief device or fuse.4 Technical requirements4.1 General provisionsThe container for vehicles using automotive LPG in their propulsion system shall function in a correct and safe way.The materials of the container shall be compatible with LPG.All necessary corrosion prevention measures shall be taken to protect the finished container including anypermanently fixed parts.4.2 DimensionsFor all dimensions without indication of tolerances, general tolerances of EN 22768-1 shall apply.4.3 SteelSteel for shells, dished ends, welded plates and rings (see annex D) shall be in accordance with EN 10120. Steelsother than those in EN 10120 may be used, provided that the container complies with the requirements of thisstandard.The container manufacturer shall ensure that all parent materials are free from defects.Container parts shall be made of materials that are compatible when welded.The filler materials shall be compatible with the material to form welds with properties equivalent to those specifiedfor the parent material (see EN 288-3).The container manufacturer shall obtain and provide chemical cast analysis certificates and mechanical propertiesof the steel used for the construction of the parts subject to pressure.The container manufacturer shall maintain a system for identification in the fabrication so that all parent materialsfor parts subject to pressure can be traced.The container manufacturer shall maintain records of the results of metallurgical and mechanical tests andanalyses of parent and filler materials.SIST EN 12805:2002



EN 12805:2002 (E)94.4 Design temperatureThe minimum design temperature shall be – 20 °C.The maximum design temperature shall be + 65 °C.For extreme operating temperatures, exceeding the above, a minimum design temperature of – 40 °C shall beapplied.4.5 Design pressureThe design pressure of the container shall be 3 000 kPa.4.6 Heat treatmentThe container manufacturer shall maintain records to demonstrate that the containers have been adequately heattreated.Localised heat treatment of a completed container shall not be permitted.The heat-treatment shall be according to the following:a) containers with a wall thickness greater than or equal to 5 mm:¾ for hot-rolled and normalized material: stress relieving or normalizing;¾ for material of a different kind: normalizing;b) containers with a wall thickness less than 5 mm:¾ normalizing the whole container, or¾ normalizing the parts having been deformed by more than 5 %.Heat treatment shall not be required if, in a tensile test carried out after forming by a standard procedure inaccordance with EN 10002-1, the elongation after rupture is 14 % or more.4.7 Calculation of the parts under pressure4.7.1 Wall thickness of the cylindrical shellThe minimum wall thickness a of the cylindrical shell shall be calculated according to the following calculation:- containers without a longitudinal weld:- containers with a longitudinal weld:For the value z see 5.2.4.2.hh5001PzRDPae+=hh5001PRDPae+=SIST EN 12805:2002



EN 12805:2002 (E)104.7.2 Non-cylindrical containersFor container shapes other than a cylindrical container the adequacy of their design shall be shown by a calculationor demonstrated by a fatigue test in accordance with 7.6 or by appropriate stress analysis. All welding requirementsfor cylindrical containers shall apply.4.7.3 Container endsContainer ends shall be in one piece, concave to the pressure, and shall be either torispherical or semi-ellipsoidal.The minimum wall thickness b of the ends after forming shall be calculated according to the following formula:The shape factor C shall be obtained from Table J.1 or Figure J.1 or Figure J.2.The difference between the wall thickness of the cylindrical edge of the ends and the shell shall be 15 % or less ofthe smallest wall thickness.The dimensions of the container ends shall fulfil the following conditions:NOTEFor illustration of container ends, see annex B.¾ Torispherical ends:r ³ 0,1 DR £ Dr ³ 2 bh ³ 4 bH ³ 0,18 D0,003 D £ b £ 0,080 Dh £ 0,15 D¾ Semi-ellipsoidal ends:H ³ 0,1 Dh ³ 4 b0,003 D £ b £ 0,080 Dh £ 0,15 DCRDPbeh5001=)](22)[(]brDbRx2D-b)[(R-b)(RH+-++++=SIST EN 12805:2002



EN 12805:2002 (E)115 Construction and workmanship5.1 General requirementsThe manufacturer shall be able to demonstrate that his quality control system ensures that the containers producedmeet the requirements of this standard.The manufacturer shall maintain records of the welding procedures and inspections that are carried out duringproduction.The manufacturer shall visually examine the pressure containing parts of the container before assembly.5.2 Welding requirements5.2.1 Welding qualificationsThe manufacturer shall qualify the welding procedures and welders before proceeding with the production ofcontainers to EN 288-3 and EN 287-1 respectively.The manufacturer shall maintain records of his welding qualifications.5.2.2 Technical welding requirementsButt welds shall be executed by an automatic or semi-automatic welding process.Butt welds on the pressure containing shell shall not be located in any areas where there are changes of profile.Angle (fillet) welds shall be at least 10 mm away from butt welds.Welded attachment points in the area of the small radius r of ends are permitted if the container fulfils therequirements of the burst test.Container welds shall satisfy the following:¾ a longitudinal weld shall be in the form of a butt weld on the full section of the wall, see Figure C.1;¾ a circumferential weld shall be in the form of a butt weld on the full section of the wall, see Figure C.2;NOTE 1A joggle weld is considered to be a special type of butt weld.¾ a weld attaching the valve boss/plate or ring to the container shall be in accordance with annex D;¾ a weld attaching a collar or support to the container shall be either a butt or an angle weld;¾ misalignment of the joint-faces of a butt weld shall not exceed 20 % of the wall thickness.Welded mounting supports shall be welded circumferentially. Welds shall be strong enough to withstand vibrationsand forces of at least 30 g in all directions, to be demonstrated by impact test or calculation.NOTE 2For details, see EN 12979.5.2.3 Shift rotating of weldsWhen the cylindrical part of the container is made of two or more parts, the longitudinal welds shall not be alignedand the distance between the welds shall be at least 10 times the wall thickness of the container, see annex E.SIST EN 12805:2002



EN 12805:2002 (E)125.2.4 Inspection of welds5.2.4.1 Visual inspection of weldsThe manufacturer shall visually inspect all container welds.During the inspection, the welded surface shall be well illuminated and shall be free from grease, dust, scaleresidue or any kind of coating.The excess thickness of welds shall not exceed 25 % of the width of the weld see Figure C.1.All welds shall have an even finish without concavity and shall merge into the parent metal without undercutting orabrupt irregularity.5.2.4.2 Radiographic inspection of weldsThe manufacturer shall ensure that all butt welds show full penetration without any deviation of the weld seam. Thefusion of the filler material with the parent steel shall be smooth and free from etching. The welds shall be free fromdefects that are likely to jeopardise the safe use of the container. This shall be demonstrated in the followingmanner:¾ for containers in two pieces, a radiographic inspection shall be performed on 100 mm of the circumferentialbutt-weld, or¾ for containers with more than two parts a radiographic inspection shall be performed on each weld intersectionand 100 mm of the adjacent longitudinal weld. The adjacent circumferential weld of each intersection shall alsobe radiographed over 25 mm on each side of the intersection, in accordance with Figure I.1.These inspections shall be performed on the first container from each shift period of a continuous production and inthe event of production being interrupted for a period of
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