Proposal for a COUNCIL DECISION on the accession by the European Community to United Nations Economic Commission for Europe Regulation No 67 on the approval of special equipment for motor vehicles fuelled by liquefied petroleum gas
(presented by the Commission)
1. General
Following Council Decision 97/836/EC of 27 November 1997, the EC has become a contracting party to the United Nations Economic Commission for Europe (UNECE) 1958 Revised Agreement on 24 March 1998 and adopted 78 regulations annexed to that Agreement.
Article 3(3) of that Decision states, in particular, that the Community may decide to apply a regulation which it had not adopted on accession to the revised agreement if, following Parliamentary assent, the Council approves that regulation by a qualified majority.
At the 116th meeting of the UNECE's "Working Party on Vehicle Design", an amendment to Regulation No 67 was adopted in respect of the approval of special equipment for motor vehicles fuelled by liquefied petroleum gas. That Regulation is not mentioned in the list of regulations recognised by the EC set out in Annex II to Decision 97/836/EC.
The amended version of Regulation No 67 is intended, in particular, to remove the technical barriers to trade in motor vehicles that exist between the contracting parties, while at the same time ensuring a high level of safety and environmental protection. It should be pointed out that the EC can only accede to the amended version of Regulation No 67 if that amendment actually takes effect on the date(s) specified therein. It is also laid down that that Regulation will be incorporated into the approval system for motor vehicles and will thus supplement the legislation in force within the Community.
It must be stressed that the EC will take its decision regarding accession to that regulation on the basis of the document available in the official languages of the UNECE (French, English and Russian). Regulation No 67 is thus annexed solely to the French and English versions.
2. Content of the proposal for a Decision
The proposal for a Decision is intended to enable the Community to accede to UNECE Regulation No 67 on the approval of special equipment for motor vehicles that are fuelled by liquefied petroleum gas.
***
Proposal for a
COUNCIL DECISION
on the accession by the European Community to United Nations Economic Commission for Europe Regulation No 67 on the approval of special equipment for motor vehicles fuelled by liquefied petroleum gas
THE COUNCIL OF THE EUROPEAN UNION,
Having regard to the Treaty establishing the European Community,
Having regard to Council Decision 97/836/EC of 27 November 1997 with a view to accession by the European Community to the Agreement of the United Nations Economic Commission for Europe concerning the adoption of uniform technical prescriptions for wheeled vehicles, equipment and parts which can be fitted to and/or be used on wheeled vehicles and the conditions for reciprocal recognition of approvals granted on the basis of these prescriptions ('Revised 1958 Agreement') (1), and in particular Article 3(3) and the second indent of Article 4(2) thereof;
(1) OJ L 346, 17.12.1997, p. 78.
Having regard to the proposal from the Commission (2),
(2) OJ C
Having regard to the assent of Parliament (3),
(3) OJ C
(1) Whereas the amended version of Regulation No 67 on the approval of special equipment for motor vehicles that are fuelled by liquefied petroleum gas will remove the technical barriers to the trade in motor vehicles between the contracting parties in respect of the special equipment fitted to such motor vehicles; whereas the uniform requirements of that Regulation ensure a high level of safety and environmental protection;
(2) Whereas the contracting parties have been notified of the amended version of Regulation No 67, which will enter into force, in all of the contracting parties not having made their disagreement known, on the date(s) specified therein in the form of a regulation annexed to the Revised 1958 Agreement;
(3) Whereas that Regulation should be incorporated into the approval system for vehicles and should thus supplement Community legislation currently in force;
Sole Article
The European Community shall accede to UNECE Regulation No 67 on the approval of special equipment for motor vehicles fuelled by liquefied petroleum gas, as amended and as notified to the contracting parties (4), if the measure or amendment enters into force on the date(s) specified therein.
(4) Cf. Document TRANS/WP.29/R. 808/Rev. 2 UNECE.
Done at Brussels,
For the Council
The President
ANNEX
(EN)
This Regulation applies to:
1.1. Part I. Approval of specific equipment of motor vehicles using liquefied petroleum gases in their propulsion system;
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.
2.1. "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:
(b) the accessories fitted to the container,
(d) the shut-off valve,
(f) the gas dosage unit, either separate or combined with the gas injection device,
(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;
>REFERENCE TO A GRAPHIC>
>REFERENCE TO A GRAPHIC>
2.3. "Container" means any vessel used for the storage of liquefied petroleum gas;
2.3.1. A container can be:
(ii) a special container: other containers than standard cylindrical containers. The dimensional characteristics are given in annex 10, appendix 5;
2.4. "Type of container" means containers which do not differ in respect of the dimensional characteristics as specified in annex 10;
2.5. "Accessories fitted to the container" means the following equipment which may be either separate or combined:
(a) 80 per cent stop valve
(c) pressure relief valve
(e) fuel pump
(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,
2.5.3. "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% 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 monofuel 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:
PART I
APPROVAL OF SPECIFIC EQUIPMENT OF MOTOR VEHICLES USING LIQUEFIED PETROLEUM GASES IN THEIR PROPULSION SYSTEM
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.
3.2. 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.
(b) the capacity in litres;
(d) test pressure [bar];
(f) approval mark according to paragraph 5.4.
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 00 for the Regulation in its original form) 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.
5.4. 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 (1).
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 directive 95/54/EEC 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
6.3.1. 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 6.14.8.3., 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 6.3.3. above shall be type-approved pursuant to the provisions laid down in annex 3 to this Regulation.
6.4.-6.13. Provisions regarding other components
>TABLE>
3/ Applicable only when the operating pressure of the gas mixing piece exceeds 20 kPa (Class 2).
6.14.1. Provisions regarding the 80% stop valve
(i) insulated in a manner that no current is lead through, LPG containing parts
- from the body
Isolation resistance shall be > 10 M*.
6.14.2.1. The electrical connections inside the boot and passengers compartment shall comply with insulation class IP 40 according to IEC 529.
6.14.2.2. All other electrical connections shall comply with insulation class IP 54 according to IEC 529.
6.14.2.3. 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.
6.14.3.1. Specific provisions on valves activated by an electric/external (hydraulic,pneumatic) power:
in which
A = exterior surface of the container in m2.
6.14.8.6. 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 m3/min (100 kPa absolute and temperature of 15?C)
6.14.8.9. The pressure relief device (fuse) shall be tested according to the provisions described in annex 3 paragraph 7.
6.14.9. Power dissipation of the fuel pump
(2) / As defined in the Consolidated Resolution on the Construction of Vehicles (R.E.3), annex 7 (document TRANS/SC1/WP29/78/Amend.3).
6.14.10.4. The outside filling unit is connected to the container by a hose or pipe.
6.14.11. Provisions regarding the level indicator
6.14.11.1. 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 electrical power connections should meet Class 1 specifications.
6.14.11.2. If the level indicator of the container comprises a float, the latter shall withstand an outside pressure of 3,000 kPa.
7. MODIFICATIONS OF A TYPE OF LPG EQUIPMENT AND EXTENSION OF APPROVAL
7.1. 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)
9.2. 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.
11. (Not allocated)
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.
14. DEFINITIONS
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.
(3) / 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 Yugoslavia, 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 (vacant), 25 for Croatia, 26 for Slovenia, 27 for Slovakia, 28 for Belarus, 29 for Estonia, 30-36 (vacant) and 37 for Turkey. 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 Conditions of Approval and Reciprocal Recognition of Approval for Motor Vehicle Equipment and Parts, and the numbers thus assigned shall be communicated by the Secretary-General of the United Nations to the Contracting Parties to the Agreement.
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.
17.1.3. 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.
17.1.7. 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 17.1.8., motor vehicles of categories M2, M3, N2, N3 and M1 having a maximum total mass > 3500 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 17.1.8.1. may 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 17.1.8., a monofuel 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 17.1.8.3. may 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. Monofuel vehicles installed with a service coupling shall carry a sticker near the service coupling as specified in annex 17.
17.1.8. Identification of LPG-fuelled M2 and M3 category vehicles.
17.1.8.1. Vehicles of category M2 and M3 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 M2 or M3 category vehicle and on the outside of the doors on the left-hand side for right hand drive vehicles and on the right-hand side for 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.
(a) 20 g in the direction of travel
(a) 10 g in the direction of travel
(a) 6.6 g in the direction of travel
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 gastight housing if that gastight housing fulfils the requirements of paragraph 17.7.5.
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%.
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 Gastight housing on the container
17.6.5.1. A gastight housing over the container fittings, which fulfils the requirements of paragraphs 17.7.5.2. to 17.7.5.5. 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 gastight 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 gastight 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 gastight housing shall have a minimum clear opening of 450 mm2.
(i) the connections on the gastight housing; and
17.11. Fuel selection system and electrical installation
17.11.1. 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 17.12.5. 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 gastight 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.
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.
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.
Annex 1
ESSENTIAL CHARACTERISTICS OF THE VEHICLE, ENGINE AND LPG-RELATED EQUIPMENT
1. DESCRIPTION OF THE ENGINE(S)
1.1. Manufacturer
1.1.1. Manufacturer's engine code(s) (as marked on the engine, or other means of identification)
1.2. Internal combustion engine
1.2.4.5. Description of the LPG fuelling equipment:
1.2.4.5.1. System description:
1.2.4.5.1.1. Make(s):
1.2.4.5.1.2. Type(s):
1.2.4.5.11. Remote filling unit: 1/
1.2.4.5.11.1. Make(s):
1.2.4.5.11.2. Type(s):
1.2.4.5.11.3. Description and drawings:
1.2.4.5.12. Flexible fuel hose(s)/pipes:
1.2.4.5.12.1. Make(s):
1.2.4.5.12.2. Type(s):
1.2.4.5.12.3. Description :
1.2.4.5.12.4. Operating pressure(s): 2/ kPa
1.2.4.5.13. Pressure and Temperature sensor(s): 1/
1.2.4.5.13.1. Make(s):
1.2.4.5.13.2. Type(s):
1.2.4.5.13.3. Description :
1.2.4.5.13.4. Operating pressure(s): 2/ kPa
1.2.4.5.14. LPG filter unit(s): 1/
1.2.4.5.14.1. Make(s):
1.2.4.5.14.2. Type(s):
1.2.4.5.14.3. Description :
1.2.4.5.14.4. Operating pressure(s): 2/ kPa
1.2.4.5.15. Service coupling(s) (monofuel vehicles without limp-home system): 1/
1.2.4.5.15.1. Make(s):
1.2.4.5.15.2. Type(s):
1.2.4.5.15.3. Description and drawings of installation:
1.2.4.5.16. Connection to LPG system for heating system: yes/no 1/
1.2.4.5.16.1. Make(s):
1.2.4.5.16.2. Type(s):
1.2.4.5.16.3. Description and drawings of installation:
1.2.4.5.17. Fuel rail: 1/
1.2.4.5.17.1. Make(s):
1.2.4.5.17.2. Type(s):
1.2.4.5.17.3. Description and drawings of installation:
1.2.4.5.17.4. Operating pressure(s): 2/ kPa
1.2.4.5.18. Further documentation:
1.2.4.5.18.1. Description of the LPG-equipment and the physical safeguarding of the catalyst at switch-over from petrol to LPG or back
1.2.4.5.18.2. System lay-out (electrical connections, vacuum connections compensation hoses, etc.)
1.2.4.5.18.3. Drawing of the symbol:
1.2.4.5.18.4. Adjustment data:
1.2.4.5.18.5. Certificate of the vehicle on petrol, if already granted:
1.2.5. Cooling system: (liquid/air) 1/
1.2.5.1. System description/drawings with regard to the LPG equipment
_______________
2/Specify the tolerance.
4/This value must be calculated with = 3,1416 and rounded off, to the nearest cm3.
TYPE-APPROVAL MARK
(See paragraph 5.2. of this Regulation)
1
67 R-002439 CLASS
a * 5 mm
.......................
.......................
.......................
concerning: 2/ APPROVAL GRANTED
APPROVAL REFUSED
of a type of LPG equipment pursuant to Regulation No. 67
Approval No.: ........... Extension No.: .........
1. LPG equipment considered:
level indicator
pressure relief valve (discharge valve)
remotely controlled service valve with excess flow valve
multivalve, including the following accessories:
gas-tight housing
1/Distinguishing number of the country which has granted/extended/refused/withdrawn approval (see approval provisions in the Regulation.)
Annex 2C
ARRANGEMENT OF APPROVAL MARKS
Model A
(See paragraph 16.2. of this Regulation)
2
67 R-002439
Model B
(See paragraph 16.2. of this Regulation)
>REFERENCE TO A GRAPHIC>
3
67 002439
a * 8 mm
Annex 2D
issued by: Name of administration:
.......................
.......................
concerning: 2/ APPROVAL GRANTED
APPROVAL REFUSED
PRODUCTION DEFINITELY DISCONTINUED
3. Vehicle category
4. Manufacturer's name and address
6. Description of the vehicle drawings etc.
7. Test results
8. Submitted for approval on
9. Technical service responsible for conducting approval tests
10. Date of report issued by that service
11. No. of report issued by that service
12. Approval granted/refused/extended/withdrawn 2/
13. Reason(s) of extension (if applicable)
14. Place
15. Date
16. Signature
17. The following documents filed with the application or extension of approval can be obtained upon request.
Drawings, diagrams and scheme plans regarding the components and the installation of the LPG equipment considered to be of importance for the purpose of this Regulation;
Where applicable drawings of the various equipment and their position in the vehicle.
______________
2/Strike out what does not apply.
1 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
1.5. General design rules:
Paragraph 6.14.2., Provisions regarding the electrical insulation.
1.6. Applicable test procedures:
Over pressure test Annex 15, para. 4
High temperature Annex 15, para. 6
Seat leakage Annex 15, para. 8
Operational test Annex 15, para. 10
Corrosion resistance Annex 15, para. 12 */
Ozone ageing Annex 15, para. 14 **/
Creep Annex 15, para. 15 **/
*/ only for metallic parts
**/ only for non-metallic parts
2. 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 6.14.11., Provisions regarding the level indicator.
Paragraph 6.14.2., Provisions regarding the electrical insulation.
2.6. Applicable test procedures:
Over pressure test Annex 15, para. 4
High temperature Annex 15, para. 6
LPG compatibility Annex 15, para. 11 **/
Resistance to dry heat Annex 15, para. 13
Creep Annex 15, para. 15 **/
Temperature cycle Annex 15, para. 16 **/
________________________
**/ only for non-metallic parts
3. 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 6.14.8., Provisions regarding the pressure relief valve (discharge valve)
3.6. Applicable test procedures:
Over pressure test Annex 15, para. 4
High temperature Annex 15, para. 6
Seat leakage Annex 15, para. 8
(with 6,000 operation cycles)
LPG compatibility Annex 15, para. 11**/
Corrosion resistance Annex 15, para. 12*/
Ozone ageing Annex 15, para. 14**/
Temperature cycle Annex 15, para. 16**/
_____________________
**/ only for non-metallic parts
4. 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 6.14.3.1., Provisions on valves activated by an electrical/external power.
External leakage Annex 15, para. 5
Low temperature Annex 15, para. 7
Endurance Annex 15, para. 9
Operational test Annex 15, para. 10
Corrosion resistance Annex 15, para. 12*/
Ozone ageing Annex 15, para. 14**/
Creep Annex 15, para. 15**/
Temperature cycle Annex 15, para. 16**/
____________________
**/ only for non-metallic parts
5. 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 6.14.2.1., Provisions regarding the electrical insulation.
External leakage Annex 15, para. 5
Low temperature Annex 15, para. 7
Corrosion resistance Annex 15, para. 12*/
Resistance to dry heat Annex 15, para. 13
Creep Annex 15, para. 15**/
______________________
*/ only for metallic parts
6. 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 6.14.12., Provisions regarding the gas-tight housing.
6.6. Applicable test procedures:
Over pressure test Annex 15, para. 4 (at 50 kPa)
High temperature Annex 15, para. 6
7. Provisions regarding the approval of the pressure relief device (fuse)
The fuse has to be designed to open at a temperature of 120?C ? 10?C
7.5. General design rules
Paragraph 6.14.2., Provisions regarding the electrical insulation
Paragraph 6.14.7., Provisions regarding the gas tube pressure relief valve
7.6. Test procedures to be applied:
Overpressure test Annex 15, par. 4
High temperature Annex 15, par. 6
Seat (if any) leakage Annex 15, par. 8
LPG compatibility Annex 15, par. 11**/
Resistance to dry heat Annex 15, par. 13
Ozone ageing Annex 15, par. 14**/
Creep Annex 15, par. 15**/
_______________________
**/ Only for non-metallic parts
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.
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 1/. 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 cm3/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.
_________________
4. Design temperatures:
For temperatures exceeding the above-mentioned values, special tests conditions are applicable.
5. General design rules:
Paragraph 6.14.2., Provisions regarding the electrical insulation.
Paragraph 6.14.3.2., Provisions when the power is switched off.
LPG compatibility Annex 15, para. 11 **/
External leakage Annex 15, para. 5
High temperature Annex 15, para. 6
Low temperature Annex 15, para. 7
LPG compatibility Annex 15, para. 11**/
Resistance to dry heat Annex 15, para. 13
Creep Annex 15, para. 15**/
*/ 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:
Components of Class 2: 450 kPa.
For temperatures exceeding the above-mentioned values, special tests conditions are applicable.
5. General design rules: (not used)
6. Applicable test procedures:
6.1. For parts of Class 1:
Over pressure test Annex 15, para. 4
High temperature Annex 15, para. 6
LPG compatibility Annex 15, para. 11**/
Corrosion resistance Annex 15, para. 12*/
Ozone ageing Annex 15, para. 14**/
Temperature cycle Annex 15, para. 16**/
6.2. For parts of Class 2 and/or 2A:
Over pressure test Annex 15, para. 4
External leakage Annex 15, para. 5
High temperature Annex 15, para. 6
Low temperature Annex 15, para. 7
LPG compatibility Annex 15, para. 11**/
Corrosion resistance Annex 15, para. 12*/
__________________
*/ only for metallic parts
**/ only for non-metallic parts
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 2: for the part which is in contact with the regulated pressure and with a maximum regulated pressure during operation of 450 kPa.
3. Classification pressure:
Parts of Class 1: 3,000 kPa.
Parts of Class 2A: 120 kPa.
For temperatures exceeding the above-mentioned values, special tests conditions are applicable.
5. General design rules:
Paragraph 6.14.2., Provisions regarding the electrical insulation.
Paragraph 6.14.4., Heat exchange medium (compatibility and pressure requirements).
Paragraph 6.14.5., Overpressure bypass security.
Paragraph 6.14.6.2., Gas flow prevention.
6. Applicable test procedures:
6.1. For parts of Class 1:
External leakage Annex 15, para. 5
Low temperature Annex 15, para. 7
Seat leakage Annex 15, para. 8
Endurance Annex 15, para. 9
LPG compatibility Annex 15, para. 11**/
Corrosion resistance Annex 15, para. 12*/
Ozone ageing Annex 15, para. 14**/
Temperature cycle Annex 15, para. 16**/
6.2. For parts of Class 2 and/or 2A:
Over pressure test Annex 15, para. 4
External leakage Annex 15, para. 5
High temperature Annex 15, para. 6
Low temperature Annex 15, para. 7
LPG compatibility Annex 15, para. 11**/
Corrosion resistance Annex 15, para. 12*/
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.
__________________
*/ only for metallic parts
**/ only for non-metallic parts
Annex 7
PROVISIONS REGARDING THE APPROVAL OF THE SHUT-OFF VALVE, THE NON-RETURN VALVE, THE GAS-TUBE PRESSURE RELIEF VALVE, THE SERVICE COUPLING
1.4. Design temperatures:
-20?C to 120?C
Paragraph 6.14.3.1., Provisions on valves activated by electrical power.
1.6. Applicable test procedures:
Over pressure test Annex 15, para. 4
High temperature Annex 15, para. 6
Low temperature Annex 15, para. 7
Endurance Annex 15, para. 9
Corrosion resistance Annex 15, para. 12*/
Resistance to dry heat Annex 15, para. 13
Creep Annex 15, para. 15**/
__________________
*/ only for metallic parts
**/ only for non-metallic parts
2. 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:
For temperatures exceeding the above-mentioned values, special tests conditions are applicable.
2.5. General design rules:
Paragraph 6.14.2., Provisions regarding the electrical insulation.
External leakage Annex 15, para. 5
High temperature Annex 15, para. 6
Seat leakage Annex 15, para. 8
LPG compatibility Annex 15, para. 11**/
Corrosion resistance Annex 15, para. 12*/
Ozone ageing Annex 15, para. 14**/
Temperature cycle Annex 15, para. 16**/
__________________
*/ only for metallic parts
**/ only for non-metallic parts
3. 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
Paragraph 6.14.3.1., Provisions on valves activated by electrical power.
Over pressure test Annex 15, para. 4
High temperature Annex 15, para. 6
Seat leakage Annex 15, para. 8
Endurance Annex 15, para. 9 (with 6,000 operation cycles)
LPG compatibility Annex 15, para. 11**/
Resistance to dry heat Annex 15, para. 13
Creep Annex 15, para. 15**/
Temperature cycle Annex 15, para. 16**/
__________________
*/ only for metallic parts
**/ only for non-metallic parts
4. 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
Paragraph 6.14.3.1., Provisions on valves activated by electrical power.
4.6. Applicable test procedures:
Over pressure test Annex 15, para. 4
External leakage Annex 15, para. 5
Low temperature Annex 15, para. 7
Endurance Annex 15, para. 9 (with 6,000 operation cycles)
LPG compatibility Annex 15, para. 11**/
Resistance to dry heat Annex 15, para. 13
Creep Annex 15, para. 15**/
Temperature cycle Annex 15, para. 16**/
__________________
*/ only for metallic parts
**/ only for non-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:
(ii) Low pressure rubber hoses (Class 2)
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
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
1.3.1. 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 %.
1.3.1.2. Resistance to n-pentane according to ISO 1817 with the following conditions:
(ii) temperature: 23?C (tolerance acc.to ISO 1817)
(i) maximum change in volume 20 %
(iii) maximum change in elongation at break 30 %
1.3.1.3. Resistance to ageing according to ISO 188 with the following conditions:
(ii) exposure period: 168 hours
Requirements:
(i) maximum change in tensile strength 25 %
(ii) maximum change in elongation at break -30 % and +10 %
1.4. Specifications and test-method for the cover
1.4.1.1. 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 %.
(i) medium: n-hexane
(iii) immersion period: 72 hours
Requirements:
(i) maximum change in volume 30 %
(iii) maximum change in elongation at break 35 %
1.4.1.3. Resistance to ageing according to ISO 188 with the following conditions:
(ii) exposure period: 336 hours
Requirements:
(ii) maximum change in elongation at break -30 % and +10 %
1.4.2. Resistance to Ozone
1.4.2.1. The test has to be performed in compliance with ISO standard 1431/1.
1.4.2.2. The test-pieces, which have to be stretched to an elongation of 20 % 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
1.5.1.2. The test has to be carried out in compliance with the method described in ISO-standard 4080.
1.5.1.3. The leakage through the wall of the hose shall not exceed 95 cm3 of vapour per metre of hose per 24 h.
1.5.2. Resistance at low temperature
1.5.2.1. The test has to be carried out in compliance with the method described in ISO-standard 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)
1.5.3.1. (Not used)
1.5.3.2. (Not used)
1.5.4. 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.
1.5.4.2.
>REFERENCE TO A GRAPHIC>
Figure 1
1.5.4.3. The testing-machine (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 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.
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.
1.7.2. The hose assembly has to be subjected to an impulse test in compliance with ISO-standard 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.
1.7.3. 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
1.8.1. 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
An intentionally provided puncture in the cover shall not be considered as an imperfection.
2.3. Specifications and tests for the lining
2.3.1. 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 %.
2.3.1.2. Resistance to n-pentane according to ISO 1817 with the following conditions:
(ii) temperature: 23?C (tolerance acc. to ISO 1817)
(i) maximum change in volume 20 %
(iii) maximum change in elongation at break 30 %
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 %.
2.3.1.3. Resistance to ageing according to ISO 188 with the following conditions:
(i) temperature: 115?C (test temperature = maximum operating temperature - 10?C)
(i) maximum change in tensile strength 25 %
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 %.
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)
Requirements:
(i) maximum change in volume 30 %
(ii) maximum change in tensile strength 35 %
(i) temperature: 115 ?C (test temperature = maximum operating temperature - 10?C)
Requirements:
(ii) maximum change in elongation at break -30 % and +10 %
2.4.2. Resistance to Ozone
2.4.2.1. The test has to be performed in compliance with ISO standard 1431/1.
2.4.2.2. The test-pieces, which have to be stretched to an elongation of 20 % 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
2.5.1. 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 ISO-standard 4080.
2.5.1.3. The leakage through the wall of the hose shall not exceed 95 cm3 of vapour per metre of hose per 24 h.
2.5.2.2. Test-temperature: -25? ± 3?C.
2.5.2.3. No cracking or rupture is allowed.
2.5.3. 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.
2.5.3.2.
>REFERENCE TO A GRAPHIC>
Figure 2
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.
2.5.4.2. The test-pressure of 1,015 kPa shall be applied during 10 minutes, without any leakage.
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.
2.7. 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.
2.7.2. The hose assembly has to be subjected to an impulse test in compliance with ISO-standard 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.
-25?C and +125?C. For operating temperatures exceeding the above- mentioned values, the test temperatures must be adapted.
3.1.4. The inside diameter shall be in compliance with table 1 of ISO standard 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).
3.2.2. The lining and the cover must be free from pores, holes and strange elements.
(i) medium: n-pentane
(iii) immersion period: 72 hours
Requirements:
(ii) maximum change in tensile strength 25 %
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 %.
3.3.1.3. Resistance to ageing according to ISO 188 with the following conditions:
(ii) exposure period: 168 hours
Requirements:
(ii) maximum change in elongation at break -30 % and +10 %
3.4. Specifications and test-method for the cover
(i) medium: n-hexane
(iii) immersion period: 72 hours
(i) maximum change in volume 30 %
(iii) maximum change in elongation at break 35 %
3.4.1.3. Resistance to ageing according to ISO 188 with the following conditions:
(ii) exposure period: 336 hours
Requirements:
(i) maximum change in tensile strength 25 %
3.4.2.2. The test-pieces, which have to be stretched to an elongation of 20 % shall have to be exposed to air of 40?C and a relative humidity of 50 % ± 10 % 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.
3.5. Specifications for uncoupled hose
3.5.1. 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.
3.5.2. Resistance at low temperature
3.5.2.2. Test-temperature: -25? ± 3?C.
3.5.2.3. No cracking or rupture is allowed.
3.5.3. 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?C ± 2?C during 24 hours.
3.5.4. Bending test
3.5.4.1. 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 3.5.5.2.
(a = 102 mm; b = 241 mm)
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 approx. 130 mm.
The circumference of the wheels must be grooved for the guidance of the hose.
3.7. Assembly of hose and couplings
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.
3.7.2. 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
3.8.1. 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.
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
For temperatures exceeding the above-mentioned values, special tests conditions are applicable.
5. General design rules:
Paragraph 6.14.2., Provisions regarding the electrical insulation.
Paragraph 6.14.10., Provisions regarding the filling unit.
6. Applicable test procedures:
Over pressure test Annex 15, para. 4
High temperature Annex 15, para. 6
Seat leakage test Annex 15, para. 8
LPG compatibility Annex 15, para. 11**/
Creep Annex 15, para. 15**/
__________________
**/ only for non-metallic parts
4
Figure 1
5
Figure 2
6
Figure 3: This filling unit applies only for motor vehicles of categories M2, M3, N2, N3 and M1 having a maximum total mass > 3500 kg. (4)
(4) / See Consolidated Resolution on the Construction of Vehicles (R.E.3), Annex 7 (document TRANS/SC1/WP29/78/Amend.3).
The meaning of symbols and terms used in this annex
Ph = hydraulic test pressure in kPa;
Pr = container bursting pressure measured in the bursting test, in kPa;
Re = minimum yield stress in N/mm2 guaranteed by the material standard;
Rm = minimum tensile strength in N/mm2 guaranteed by the material standard
Rmt = actual tensile strength, in N/mm2;
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;
L = length of container's stress-resistant shell, in mm;
-20 to 65?C.
>REFERENCE TO A GRAPHIC>
>REFERENCE TO A GRAPHIC>
r * 0.1 D
H * 0.18 D
h * 0.15 D (not applicable for containers as shown in appendix 2 to this annex, Figure 2a)
Elliptical ends
simultaneous limits:
H * 0.18 D
h * 0.15 D (not applicable for containers as shown in appendix 2 to this annex, Figure 2a)
1.5.2.3. The thickness of these barrelled ends must not in toto be less than the figure calculated by means of the following formula:
3
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.
1.5.3. The nominal wall thickness of the cylindrical part and of the barrelled end may not, under any circumstances; be less than:
>REFERENCE TO A GRAPHIC>
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 be at least equal to that guaranteed for the parent metal irrespective of where the burst occurs in the cross-section of the central part of the test-piece.
2.1.2.3. Bend test
2.1.2.3.1. The procedure for carrying out the bend test is that given in the appropriate Euronorm in accordance with paragraph 2.1.1.1. The bend test must, however, be carried out transversely to the weld on a test-piece 25 mm in width. The mandrel must be placed in the centre of the weld while the test is being performed.
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:
Actual tensile strength
Up to 440
inclusive
above 440 to 520
inclusive
above 520 // 2
3
4
2.1.2.4. Retesting is permitted for the tensile and bend test. A second test shall consist of two test pieces taken from the same container.
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
2.2.1. 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 flowrate during the test should not exceed 3 per cent of the capacity of the container per minute.
2.2.2. Interpretation of test
2.2.2.1. The criteria adopted for the interpretation of the burst test are as follows:
2.2.2.1.1. Volumetric expansion of the 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.
bursting pressure;
volume of water used between the time when the pressure starts to rise and the time of bursting, which shows the volumetric expansion of the container;
examination of the tear and the shape of its edges.
2.2.3. Test acceptance conditions
2.2.3.1. The measured bursting pressure (Pr) must not under any circumstances be less than 2.25 ? 3,000 = 6,750 kPa.
2.2.3.2. The specific change in the volume of the container at the time of bursting must not be less than:
20 per cent if the length of the container is greater than the diameter;
17 per cent if the length of the container is equal to or less than the diameter.
8 per cent in the case of a special container as shown in appendix 5, page 1, Figures A, B and C.
2.2.3.3. 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. 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.
2.2.3.4. 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.
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.
2.4. Non-destructive examination
2.4.1. 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 ISO standard 2504, paragraph 6.
2.4.1.4. 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 2 a mm2.
2.4.1.4.2. For the container wall thickness REFERENCE TO A GRAPHIC>
>REFERENCE TO A GRAPHIC>
FIGURE 3: EXAMPLES OF WELDED STUDDED PLATES
>REFERENCE TO A GRAPHIC>
____________
>REFERENCE TO A GRAPHIC>
(a) tensile test on parent material
(c) tensile test on a longitudinal weld
(e) bend test on a longitudinal weld, the inner surface in tension
(g) bend test on a circumferential weld, the inner surface in tension
(m1, m2) macrosections through valve boss/plate welds (side-mounted valve block)
FIGURE 1: Containers with longitudinal and circumferential welds, Location of test-pieces
Annex 10 - Appendix 2 (cont'd)
>REFERENCE TO A GRAPHIC>
(d) tensile test on a circumferential weld
(g) bend test on a circumferential weld, the inner surface in tension
(h) bend test on a circumferential weld, the outer surface in tension
(Refer to figure 2a for other locations of test-pieces)
FIGURE 2b: Containers with circumferential welds only and valve boss/plate fitted to the end.
13
Annex 10 - Appendix 4
>REFERENCE TO A GRAPHIC>
14
>REFERENCE TO A GRAPHIC>
15
Annex 10 - Appendix 4 (cont'd)
>REFERENCE TO A GRAPHIC>
16
>REFERENCE TO A GRAPHIC>
17
EXAMPLES OF SPECIAL VESSELS
Annex 10 - Appendix 5 (cont'd)
>REFERENCE TO A GRAPHIC>
Annex 11
1. Gas injection device or injector
-20?C to 120?C
1.5. General design rules:
Paragraph 6.14.2., Provisions regarding the insulation class.
Paragraph 6.14.4.1., Heat exchange medium (compatibility and pressure requirements).
1.6. Applicable test procedures:
Over pressure test Annex 15, para. 4
High temperature Annex 15, para. 6
Corrosion resistance Annex 15, para. 12*/
Resistance to dry heat Annex 15, para. 13
Creep Annex 15, para. 15**/
*/ only for metallic parts
2. Gas injection device or gas mixing piece
2.2. Component classification (according to figure 1, para. 2):
Class 2: for the part with a maximum regulated pressure during operation of 450 kPa.
Parts of Class 2: 450 kPa.
2.4. Design temperatures:
For temperatures exceeding the above-mentioned values, special tests conditions are applicable.
2.5. General design rules:
Paragraph 6.14.2., Provisions regarding the electrical insulation.
Paragraph 6.14.3.1., Provisions when the power is switched off.
Over pressure test Annex 15, para. 4
High temperature Annex 15, para. 6
LPG compatibility Annex 15, para. 11**/
Corrosion resistance Annex 15, para. 12*/
__________________
**/ only for non-metallic parts
3. Fuel rail
3.1. Definition: see paragraph 2.18. of this Regulation.
3.2. Component classification (according to figure 1, para. 2):
Fuel rails can be of Class 1, 2 or 2A.
3.3. Classification pressure:
Parts of Class 1: 3,000 kPa.
Parts of Class 2: 450 kPa.
For temperatures exceeding the above-mentioned values, special tests conditions are applicable.
3.5. General design rules: (not used)
Over pressure test Annex 15, para. 4
High temperature Annex 15, para. 6
LPG compatibility Annex 15, para. 11**/
Corrosion resistance Annex 15, para. 12*/
Ozone ageing Annex 15, para. 14**/
Temperature cycle Annex 15, para. 16**/
3.6.2. For fuel rails of Class 2 and/or 2A:
External leakage Annex 15, para. 5
Low temperature Annex 15, para. 7
LPG compatibility Annex 15, para. 11**/
Corrosion resistance Annex 15, para. 12*/
__________________
*/ only for metallic parts
**/ only for non-metallic parts
Annex 12
Class 2A: for the part with a maximum regulated pressure during operation of 120 kPa.
3. Classification pressure:
Parts of Class 2: 450 kPa.
4. Design temperatures:
For temperatures exceeding the above-mentioned values, special tests conditions are applicable.
5. General design rules:
Paragraph 6.14.2., Provisions regarding the electrical insulation.
Paragraph 6.14.3.1., Provisions on valves activated by electrical power.
Paragraph 6.14.4., Heat exchange medium (compatibility and pressure requirements).
Paragraph 6.14.5., Overpressure bypass security.
6. Applicable test procedures:
Over pressure test Annex 15, para. 4
External leakage Annex 15, para. 5
High temperature Annex 15, para. 6
Low temperature Annex 15, para. 7
Corrosion resistance Annex 15, para. 12*/
Remarks:
The parts of the gas dosage unit (Class 2 or 2A) shall be leakproof with the outlet(s) of that part closed.
For the overpressure test all the outlets including those of the coolant compartment shall be closed off.
__________________
Annex 13
PROVISIONS REGARDING THE APPROVAL OF THE PRESSURE AND/OR TEMPERATURE SENSOR
1. Definition:
Pressure sensor: see paragraph 2.13. of this Regulation.
2. Component classification (according to figure 1, para. 2):
Pressure and temperature sensors can be of Class 1, 2 or 2A.
3. Classification pressure:
Parts of Class 2: 450 kPa.
Parts of Class 2A: 120 kPa.
-20?C to 120?C
For temperatures exceeding the above-mentioned values, special tests conditions are applicable.
5. General design rules:
Paragraph 6.14.2., Provisions regarding the electrical insulation.
Paragraph 6.14.4.1., Heat exchange medium (compatibility and pressure requirements).
Paragraph 6.14.6.2., Gas flow prevention.
6. Applicable test procedures:
6.1. For parts of Class 1:
Over pressure test Annex 15, para. 4
External leakage Annex 15, para. 5
Low temperature Annex 15, para. 7
Corrosion resistance Annex 15, para. 12*/
Resistance to dry heat Annex 15, para. 13
Creep Annex 15, para. 15**/
__________________
**/ only for non-metallic parts
6.2. For parts of Class 2 or 2A:
Over pressure test Annex 15, para. 4
High temperature Annex 15, para. 6
Low temperature Annex 15, para. 7
LPG compatibility Annex 15, para. 11**/
*/ only for metallic parts
**/ only for non-metallic parts
1. The electronic control unit can be any device which controls the LPG demand of the engine and establishes the cut-off of the remotely-controlled service valve(s), cut-off valves and fuel pump of the LPG-system in case of a broken fuel supply pipe or/and in case of stalling of the engine.
2. The switching off delay of the service cut-off valves after stalling of the engine may not be more then 5 seconds.
3. The electronic control unit shall comply with relevant electromagnetic compatibility (E.M.C) requirements according to Regulation No. 10, 02 series of amendments or equivalent.
4. Electrical failure of the vehicle system may not lead to uncontrolled opening of any valve.
5. The output of the electronic control unit shall be inactive when the electric power is switched off or removed.
Annex 15 1/
TEST PROCEDURES
1. Classification
1.1. LPG components for use in vehicles shall be classified with regard to the maximum operating pressure and function, according to Chapter 2 of this Regulation.
1.2 The classification of the components determines the tests which have to be performed for type approval of the components or parts of the components.
2. Applicable test procedures
In table 1 the applicable test procedures dependent on the classification are shown.
Table 1
>TABLE>
1/ For parts subjected to a functional test see paragraph 8 of this annex.
3/ Only applicable for parts mentioned in paragraph 8.
(i) temperature
(iii) LPG compatibility
3.1. Leakage tests shall have to be conducted with pressurized gas like air or nitrogen.
Table 2 shows the classification pressure and the pressures to be used in the over-pressure test according to the classification:
>TABLE>
5.1. A component shall be free from leakage through stem or body seals or other joints, and shall not show evidence of porosity in casting when tested as described in paragraph 5.3. at any aerostatic pressure between 0 and the pressure shown in table 3.
5.2. The test shall be performed at the following conditions:
(i) at room temperature
(iii) at the maximum operating temperature
The maximum and minimum operating temperatures are given in the annexes.
5.3. During this test the equipment under test (EUT) will be connected to a source of aerostatic pressure (of 1.5 times the maximum pressure and in the case of a class 3 component, 2.25 times the maximum classification pressure). A positive shut-off valve and a pressure gauge having a pressure range of not less than 1.5 times nor more than 2 times the test pressure are to be installed in the pressure supply piping. The pressure gauge is to be installed between the positive shut-off valve and the sample under test. While under the applied test pressure, the sample should be submerged in water to detect leakage or any other equivalent test method (flow measurement or pressure drop).
Table 3: the classification and leakage test pressures according to the classification:
Table 3
5.4. The external leakage must be lower than the requirements stated in the annexes or, if no requirements are mentioned, the external leakage shall be lower than 15 cm3/hour with the outlet plugged, when submitted to a gas pressure equal to the leakage test pressure.
6. High temperature test
A LPG containing component shall not leak more than 15 cm3/hour with the outlet plugged when submitted to a gas pressure at maximum operating temperature, as indicated in the annexes, equal to the leakage test pressure (Table 3, paragraph 5.3.). The component shall be conditioned for at least 8 hours at this temperature.
7. Low temperature test
(1) the end of the outlet tube is located approximately 13 mm above the water level within the inverted graduated cylinder, and
5
V1 = leakage rate, cubic centimetres of air or nitrogen per hour.
Vt = increase in volume within graduated cylinder during test.
t = time of test, minutes.
P = barometric pressure during test, in kPa.
T = ambient temperature during test, in K.
8.1.3. Instead of the method described above, leakage may be measured by a flowmeter installed on the inlet side of the valve under test. The flowmeter shall be capable of indicating accurately, for the test fluid employed, the maximum leakage flow rates permitted.
8.2. The seat of a shut-off valve, when in the closed position, shall be free from leakage at any aerostatic pressure between 0 to 3,000 kPa.
8.3. A non-return valve provided with a resilient seat, when in the closed position, shall not leak when subjected to any aerostatic pressure between 50 and 3,000 kPa.
8.4. A non-return valve provided with a metal-to-metal seat, when in the closed position, shall not leak at a rate exceeding 0.50 dm3/hour of air when subjected to an inlet pressure up to the test pressure according to Table 3 in paragraph 5.3.
8.5. The seat of the upper non-return valve used in the assembly of a filling unit, when in the closed position, shall be free from leakage at any aerostatic pressure between 50 and 3,000 kPa.
8.6. The seat of a service coupling, when in the closed position, shall be free from leakage at any aerostatic pressure between 0 to 3,000 kPa.
8.7. The gas-tube pressure relief valve shall not have internal leakage up to 3,000 kPa.
8.8. The pressure relief valve (discharge valve) shall not have internal leakage up to 2,300 kPa.
9. Endurance test
9.1. A filling unit or service valve shall be capable of conforming to the applicable leakage test requirements of paragraphs 5 and 8, after being subjected to a number of cycles of opening and closing as mentioned in the annexes.
9.2. A shut-off valve is to be tested with the valve outlet plugged. The valve body filled with n-hexane, and the valve inlet subjected to a pressure of 3,000 kPa.
9.3. An endurance test is to be conducted at a rate not faster than 10 times per minute. For a shut-off valve, the closing torque is to be consistent with the size of handwheel, wrench, or other means employed to operate the valve.
9.4. The appropriate tests for external and seat leakage, as described under external leakage test under paragraph 5 and seat leakage test under paragraph 8 are to be conducted immediately following the endurance test.
10. Operational tests
10.1. Operation test of the (gas-tube) pressure relief valve
10.1.1. In the case of pressure relief valves, three samples of each size, design, and setting are to be used for start-to-discharge and resealing pressure tests. This same set of three valves is to be used for flow capacity tests for other observations indicated in the following paragraphs.
Not less than two successive start-to-discharge and resealing pressure observations are to be made on each of the three test valves under test No. 1 and 3 of paragraphs 10.1.2. and 10.1.4. below.
10.1.2. Start-to-discharge and resealing pressures of pressure relief valves - test No. 1
10.1.2.1. Before being subjected to a flow capacity test, the start-to-discharge pressure of each of three samples of a pressure relief valve of a specific size, design, and setting shall be within + 3 per cent of the average of the pressures, but the start-to-discharge pressure of any one of the three valves shall be not less than 95 per cent, not more than 105 per cent, of the set pressure marked on the valve.
10.1.2.2. The resealing pressure of a pressure relief valve before being subjected to a flow capacity test shall be not less than 90 per cent of the initially observed start-to-discharge pressure.
10.1.2.3. A pressure relief valve is to be connected to an air or other aerostatic supply source capable of being maintained at a pressure of at least 500 kPa effective pressure above the marked set pressure of the valve being tested. A positive shut-off valve and a pressure gauge having a pressure range of not less than 1.5 times nor more than 2 times the test pressure are to be installed in the pressure supply piping. The pressure gauge is to be installed in the piping between the valve being tested and the positive shut-off valve. Start-to-discharge and resealing pressure are to be observed through a water seal not over 100 mm in depth.
10.1.2.4. After recording the start-to-discharge pressure of the valve, the pressure is to be increased sufficiently above the start-to-discharge pressure to ensure unseating of the valve. The shut-off valve is then to be closed tightly and the water seal, as well as the pressure gauge, are to be observed closely. The pressure at which bubbles through the water seal cease is to be recorded as the resealing pressure of the valve.
10.1.3. Flow capacity of pressure relief valves - test No. 2
10.1.3.1. The flow capacity of each of three samples of a pressure relief valve of a specific size, design, and setting shall fall within a range of 10 per cent of the highest observed capacity.
10.1.3.2. During flow capacity tests on each valve, there shall be no evidence of chattering or other abnormal operating condition.
10.1.3.3. The blow-down pressure of each valve shall be not less than 65 per cent of the initially recorded start-to-discharge pressure.
10.1.3.4. A flow capacity test on a pressure relief valve is to be conducted at a flow rating pressure of 120 per cent of the maximum set pressure.
10.1.3.5. A flow capacity test on a pressure relief valve is to be conducted by utilizing a properly designed and calibrated orifice flowmeter of the flange type connected to a source of air supply of adequate capacity and pressure. Modifications of the flowmeter from that described herein, and an aerostatic flow medium other than air, may be used provided the end results are the same.
10.1.3.6. The flowmeter is to be arranged with sufficiently long lengths of pipe both preceding and following the orifice, or other arrangements including straightening vanes, to assure no disturbance at the orifice place for the ratios of orifice to pipe diameters to be employed.
Flanges between which the orifice plate is located and clamped are to be provided with pressure take-off lines connected to a manometer. This instrument indicates the pressure differential across the orifice plate and the reading is used in the flow calculation. A calibrated pressure gauge is to be installed in that portion of the meter pipe downstream of the orifice plate. This gauge indicates the flow pressure and the reading is also used in the flow calculation.
10.1.3.7. A temperature-indicating instrument is to be connected to the meter pipe downstream of the orifice plate to indicate the temperature of the air flowing to the safety valve. The reading of this instrument is to be integrated in the calculation to correct the temperature of the air flow to a 15?C base temperature. A barometer is to be available for indicating the prevailing atmospheric pressure.
The reading of the barometer is to be added to the indicated air-flow gauge pressure. This absolute pressure is similarly to be integrated in the flow calculation. The air pressure to the flowmeter is to be controlled by a suitable valve installed in the air-supply piping ahead of the flowmeter. The pressure relief valve under test is to be connected to the discharge end of the flowmeter.
10.1.3.8. After all preparations for flow capacity tests have been made, the valve in the air-supply line is to be opened slowly and the pressure to the valve under test is to be increased to the appropriate flow rating pressure. During this interval, the pressure at which the valve "pops" open is to be recorded as the popping pressure.
10.1.3.9. The predetermined flow rating pressure is to be maintained constant for a brief interval until the readings of the instruments become stabilized. Readings of the flow pressure gauge, pressure differential manometer, and the flowing air temperature indicator are to be recorded simultaneously. The pressure is then to be decreased until there is no further discharge from the valve.
The pressure at which this occurs is to be recorded as the blow-down pressure of the valve.
10.1.3.10. From the recorded data and the known orifice coefficient of the flowmeter, the air-flow capacity of the pressure relief valve tested is to be calculated using the following formula:
6
10.2.1. An excess flow valve shall operate at not more than 10 per cent above, nor less than 20 per cent below the rated closing flow capacity specified by the manufacturer, and shall close automatically at a pressure differential across the valve of not more than 100 kPa during the operation tests described below.
10.2.2. Three samples of each size and style of valve are to be subjected to these tests. A valve intended for use only with liquid is to be tested with water, otherwise the tests are to be made both with air and with water. Except as indicated in paragraph 10.2.3., separate tests are to be run with each sample installed in vertical, horizontal and inverted positions. The tests with air to be made without piping or other restriction connected to the outlet of the tests sample.
10.2.3. A valve intended for installation in one position only may be tested only in that position.
10.2.4. The test with air is to be conducted by utilizing a properly designed and calibrated orifice flowmeter of the flange type, connected to a source of air supply of adequate capacity and pressure.
10.2.5. The test sample is to be connected to the outlet of the flowmeter. A manometer or calibrated pressure-gauge reading in increments of not more than 3 kPa is to be installed on the upstream side of the test sample to indicate the closing pressure.
10.2.6. The test is conducted by slowly increasing the flow of air through the flowmeter until the check valve closes. At the instant of closing, the pressure differential across the flowmeter orifice and the closing pressure indicated by the gauge are to be recorded. The rate of flow at closing is then to be calculated.
10.2.7. Other types of flowmeters and a gas, other than air, may be used.
10.2.8. The test with water is to be conducted using a liquid flowmeter (or equivalent) installed in a piping system having sufficient pressure to provide the required flow. The system is to include an inlet piezometer or pipe at least one pipe size larger than the valve to be tested, with a flow control valve connected between the flowmeter and piezometer. A hose or hydrostatic relief valve, or both, may be used to reduce the effect of the pressure shock when the excess flow valve closes.
10.2.9. The test sample is to be connected to the outlet end of the piezometer. A manometer or calibrated pressure gauge of the retard type, which will permit readings in the range of 0 to 1,440 kPa is to be connected to a pressure take-off on the upstream side of the test sample to indicate the closing pressure. The connection is to be made using a length of rubber hose between the pressure gauge and the pressure take-off, with a valve installed at the gauge inlet to permit bleeding air from the system.
10.2.10. Prior to the test, the flow control valve is to be opened slightly, with the bleed valve at the pressure gauge open, to eliminate air from the system. The bleed valve is then to be closed and the test is conducted by slowly increasing the flow until the check valve closes. During the test the pressure gauge is to be positioned at the same level as the test sample. At the instant of closing, the rate of flow and closing pressure are to be recorded. When the excess flow valve is at cut-off position, the leakage or by-pass rate of flow is to be recorded.
10.2.11. An excess flow valve used in the assembly of a filling unit shall close automatically at a pressure differential of not more than 138 kPa when tested as described below.
10.2.12. Three samples of each size of valve are to be subjected to these tests. The tests are to be made with air, and separate tests are to be run with each sample mounted vertically and horizontally. The tests are to be conducted as described in paragraphs 10.2.4. to 10.2.7., with a filling unit hose coupling connected to the test sample and with the upper non-return valve held in the open position.
10.3. Charging-speed-test
10.3.1. Testing of the good function of the device limiting the filling degree of the container has to be performed by filling speeds of 20, 50 and 80 l/min.
10.4. Endurance-test for the filling limiter
The device limiting the filling degree of the container shall be capable of withstanding 6,000 complete filling cycles to the maximum filling degree.
10.5. Vibration test procedure
10.5.1. Scope
Any device limiting the filling degree of the container and operating by a float, after having been subjected to the tests verifying that:
It limits the degree of filling of the container to 80 per cent or less of its capacity;
It does not allow - at the cut-off position - any filling of the container at a rate exceeding 1 litre/minute,
shall be subjected to one of the test procedures laid down in paragraph 10.5.5. or 10.5.6. below to ensure that the device is constructed to withstand expected dynamic vibrational stresses and to ensure that performance degradations or malfunctions will not be produced by the service vibration environment.
10.5.2. Equipment and mounting techniques
The test item shall be attached to the vibration equipment by its normal mounting means, either directly to the vibration exciter or transition table, or by means of a rigid fixture capable of transmitting the specified vibration conditions. Equipment used to measure and/or record the acceleration level or amplitude level and the frequency shall have an accuracy of at least 10 per cent of the measured value.
10.5.3. Choice of procedure
At the choice of the authority granting type-approval the tests shall be performed according to either procedure A described in paragraph 10.5.5. or procedure B described in paragraph 10.5.6.
10.5.4. General
The following tests shall be carried out along each of the three orthogonal axes of the test item.
10.5.5. Procedure A
10.5.5.1. Resonance search
Resonant frequencies of the filling limiter shall be determined by varying the frequency of applied vibration slowly through the specified range at reduced test levels but with sufficient amplitude to excite the item. Sinusoidal resonance search may be performed using the test level and cycling time specified for the cycling test, provided the resonance search time is included in the required cycling test time of paragraph 10.5.5.3.
10.5.5.2. Resonance dwell test
The test item shall be vibrated for 30 minutes along each axis at the most severe resonant frequencies determined in paragraph 10.5.5.1. The test level shall be 1.5 g (14.7 m/sec2). If more than four significant resonant frequencies are found for any one axis, the four most severe resonant frequencies shall be chosen for this test. If a change in the resonant frequency occurs during the test, its time of occurrence shall be recorded and immediately the frequency shall be adjusted to maintain the peak resonance condition. The final resonant frequency shall be recorded. The total dwell test time shall be included in the required cycling test time of paragraph 10.5.5.3.
10.5.5.3. Sinusoidal cycling test
The test item shall be sinusoidally vibrated for three hours along each of its orthogonal axes in accordance with:
an acceleration level of 1.5 g. (14.7 m/sec2),
a frequency range of 5 to 200 Hz,
a sweep time of 12 minutes.
The frequency of applied vibration shall be swept over the specified range logarithmically.
The specified sweep time is that of an ascending plus a descending sweep.
10.5.6. Procedure B
10.5.6.1. The test shall be performed on a sinusoidal vibrating bench, at a constant acceleration of 1.5 g and at frequencies ranging between 5 and 200 Hz. The test shall last for 5 hours for each of the axes specified in paragraph 10.5.4. The frequency band 5-200 Hz shall be covered in each of the two senses in 15 minutes.
10.5.6.2. Alternatively, in case the test is not conducted by utilizing a constant acceleration bench, the frequency band from 5 to 200 Hz has to be subdivided in 11 semi-octave bands, each of them covered by a constant amplitude, so that the theoretical acceleration is included between 1 and 2 g (g = 9.8 m/sec2).
Vibration amplitudes for each band are as follows:
>TABLE>
filling degree at the cut-off position,
(ii) temperature: 23 ?C (tolerance acc.to ISO 1817)
11.2. Requirements:
After storage in air with a temperature of 40?C for a period of 48 hours the mass compared to the original value may not decrease more than 5 %.
12. Corrosion resistance
12.1. A metal LPG containing component shall comply with the leakage tests mentioned in 4, 5, 6 and 7 and after having been submitted to 144 hours salt spray test according to DIN 50021 or ISO 9227, with all connections closed,
or an optional test:
12.1.1. A metal LPG containing component shall comply with the leakage tests mentioned in 4, 5, 6 and 7 and after having been submitted to a salt spray test according to IEC 68-2-52 Kb: Salt Spray Fog Test.
Test procedure:
Before the test the component shall be cleaned according to the instructions of the manufacturer. All the connections shall be closed off. The component shall not be operated during the test.
Subsequently the component shall be submitted during 2 hours to spraying with a solution of salt, containing 5% NaCl (mass %) with less than 0.3 % contamination and 95% distilled or demineralised water, at a temperature of 20?C. After the spraying the component is stored at temperature of 40?C and 90-95% relative humidity for 168 hours. This sequence shall be repeated 4 times.
After the test the component shall be cleaned and dried during 1 hour at 55?C. The component shall now be conditioned to reference conditions during 4 hours, before submitting it to further testing.
12.2. A copper or brass LPG containing component shall comply with the leakage tests mentioned in 4, 5, 6 and 7 and after having been submitted to 24 hours immersion in Ammonia according to DIN 50916 or ISO 6957 with all connections closed.
13. Resistance to dry-heat
The test has to be done in compliance with ISO 188. The test piece has to be exposed to air at a temperature equal to the maximum operating temperature for 168 hours.
The allowable change in tensile strength should not exceed + 25 %.
Maximum decrease 30 %
14. Ozone ageing
14.1. The test has to be in compliance with ISO 1431/1.
The test piece, which has to be stressed to 20 % elongation shall be exposed to air at 40?C with an ozone concentration of 50 parts per hundred million during 120 hours.
14.2. No cracking of the test piece is allowed.
15. Creep
A non metallic part containing liquid LPG shall comply with the leakage tests mentioned in paragraphs 5, 6 and 7 after having been submitted to a hydraulic pressure of 2.25 times the maximum operating pressure at a temperature of 120?C during minimal 96 hours. Water or any other suitable hydraulic fluid may be used as a test medium.
16. Temperature cycle test
A non metallic part containing liquid LPG shall comply with the leakage tests mentioned in paragraphs 5, 6 and 7 after having been submitted to a 96 hours temperature cycle from the minimum operating temperature up to the maximum operating temperature with a cycle time of 120 minutes, under maximum working pressure.
Annex 16
PROVISIONS REGARDING LPG IDENTIFICATION MARK FOR M2 AND M3 CATEGORY VEHICLES
>REFERENCE TO A GRAPHIC>
19
Background : green
Letters : white or white reflecting
Dimensions
Character height : * 25 mm
Sticker width : 110 - 150 mm
PROVISIONS REGARDING IDENTIFICATION MARK FOR SERVICE COUPLING
PURPOSES ONLY
Background : red
Letters : white or white reflecting
Dimensions
Character thickness : * 1 mm
Sticker width : 70 - 90 mm
Sticker height : 20 - 30 mm
The text "FOR SERVICE PURPOSES ONLY" must be centred in the middle of the sticker.