LIST OF ANNEXES

Requirements for hydrogen components other than containers designed to use compressed (gaseous) hydrogen

Requirements for the installation of hydrogen components and systems designed to use compressed (gaseous) hydrogen on hydrogen powered vehicles

Requirements for hydrogen components and systems designed to use compressed (gaseous) hydrogen and their installation on hydrogen powered vehicles

Requirements for hydrogen components other than containers designed to use liquid hydrogen

Requirements for the installation of hydrogen components and systems designed to use liquid hydrogen on hydrogen powered vehicles

Requirements for hydrogen components and systems designed to use liquid hydrogen and their installation on hydrogen powered vehicles

Administrative documents for EC type-approval of vehicles with regard to hydrogen propulsion

(8) If the means of identification of type contains characters not relevant to describe the vehicle, component or separate technical unit types covered by this information document, such characters shall be represented in the documentation by the symbol ‘?’ (e.g. ABC??123??).

(5) May be replaced by other dimensions defining the shape of the container.

(4) Classified according to the definitions set out in Part A of Annex II to Directive 2007/46/EC.

(3) If the means of identification of type contains characters not relevant to describe the vehicle, component or separate technical unit types covered by this information document, such characters shall be represented in the documentation by the symbol ‘?’ (e.g. ABC??123??).

(1) Delete where not applicable (there are cases where nothing needs to be deleted when more than one entry is applicable).

2. Manufacturers shall make the information specified in section 1 available to approval authorities and the competent authorities in the Member States responsible for the periodic inspection of vehicles in the form of manuals or by means of electronic media (e.g. CD-ROM, on-line services).

information on the need for periodic inspection and the necessary frequency in the owners’ manual of the vehicle or by means of a label close to the location of the statutory plate according to Council Directive 76/114/EEC (11) .

recommendations for inspection or testing of the hydrogen system during its service life;

Type-approval number of each hydrogen component or system installed on the vehicle type to comply with this Regulation

1.1. Vehicle equipped with hydrogen system designed to use liquid hydrogen / hydrogen system designed to use compressed (gaseous) hydrogen (10)

relating to EC type-approval of a vehicle with regard to hydrogen propulsion

0.9. Name and address of the manufacturer's representative (if any):

Means of identification of type, if marked on the vehicle (8) :

with regard to Regulation (EC) No 79/2009, as implemented by Regulation (EU) No 406/2010.

of a type of a vehicle with regard to hydrogen propulsion (7)

The manufacturer hereby states that the container design is suitable for use during the specified service life in the service conditions set out in section 2.7 of Annex IV to Regulation (EU) No 406/2010.

Composite manufacturing processes and auto-frettage according to section 3.7.2. of Part 2 to Annex IV for the manufacturing of type 2, 3 and 4 containers designed to use compressed (gaseous) hydrogen

Tube extrusion, cold deformation, tube drawing, end forming, welding, heat treatment and cleaning processes for the metal manufacturing of all containers designed to use liquid hydrogen and type 1, 2 and 3 containers designed to use compressed (gaseous) hydrogen

Reference to this Regulation and the container type

Container drawings shall show at least the following information:

Layout of cooling/heating system(s) including Nominal or Maximum Allowable Working Pressure (NAWP or MAWP) and operating temperatures …

Number of filling cycles or duty cycles as appropriate (1) : …

Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2) : …

Number of filling cycles or duty cycles as appropriate (1) : …

Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2) : …

Other adjustment possibilities: if so and which (description and drawings): …

Number of filling cycles or duty cycles as appropriate (1) : …

Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2) : …

Number of filling cycles or duty cycles as appropriate (1) : …

Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2) : …

Number of filling cycles or duty cycles as appropriate (1) : …

Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2) : …

Number of filling cycles or duty cycles as appropriate (1) : …

Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2) : …

Number of filling cycles or duty cycles as appropriate (1) : …

Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2) : …

Number of filling cycles or duty cycles as appropriate (1) : …

Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2) : …

Number of filling cycles or duty cycles as appropriate: …

Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (2) : …

Number of filling cycles or duty cycles as appropriate (1) : …

Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2) : …

Number of filling cycles or duty cycles as appropriate (1) : …

Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2) : …

Manufacturer's system code(s) (as marked on the system, or other means of identification): …

Name and address of the manufacturer(s) of the hydrogen system used for the propulsion of the vehicle: …

Hydrogen system designed to use liquid hydrogen / Hydrogen system designed to use compressed (gaseous) hydrogen (1)

Name and address of the manufacturer's representative (if any): …

Means of identification of type, if marked on the vehicle (1) (3) : …

If the systems or components have electronic controls, information concerning their performance shall be supplied.

The following information shall be supplied in triplicate and include a list of contents. Any drawings shall be supplied in appropriate scale and in sufficient detail on size A4 or on a folder of A4 format. Photographs, if any, shall show sufficient detail.

relating to EC type-approval of a vehicle with regard to hydrogen propulsion

Administrative Documents for EC type-approval of vehicles with regard to hydrogen propulsion

(6) If the means of identification of type contains characters not relevant to describe the vehicle, component or separate technical unit types covered by this information document, such characters shall be represented in the documentation by the symbol ‘?’ (e.g. ABC??123??).

(3) May be replaced by other dimensions defining the shape of the container.

(1) Delete where not applicable (there are cases where nothing needs to be deleted when more than one entry is applicable).

Legend: the above component type-approval was issued by Belgium under number 0004. The first two digits (00) indicate that the component was approved according to this Regulation.

3. An example of a component type-approval mark is contained in the Addendum.

2. The component type-approval mark is affixed to the component or system in such a way as to be indelible and clearly legible.

1.2. In the vicinity of the rectangle the ‘base approval number’ contained in Section 4 of the type-approval number preceded by the two figures indicating the sequence number assigned to this Regulation or the latest major technical amendment to Regulation (EC) No 79/2009 or this Regulation. For this Regulation, the sequence number is 00.

1.1. a rectangle surrounding the lower-case letter ‘e’ followed by the distinguishing letter(s) or number of the Member State which has granted the EC component type-approval:

3. Restriction of use of the device (if any):

1.1. Hydrogen system designed to use liquid hydrogen / Hydrogen system designed to use compressed (gaseous) hydrogen / Hydrogen component designed to use liquid hydrogen / Hydrogen component designed to use compressed (gaseous) hydrogen (7)

0.9. Name and address of the manufacturer's representative (if any):

0.7. In the case of components and separate technical units, location and method of affixing of the EC approval mark:

Means of identification of type, if marked on the component (6)

with regard to Regulation (EC) No 79/2009, as implemented by Regulation (EU) No 406/2010.

The manufacturer hereby states that the container design is suitable for use during the specified service life in the service conditions set out in section 2.7 of Annex IV to Regulation (EU) No 406/2010.

Composite manufacturing processes and auto-frettage according to section 3.7.2. of Part 2 to Annex IV for the manufacturing of type 2, 3 and 4 containers designed to use compressed (gaseous) hydrogen

Tube extrusion, cold deformation, tube drawing, end forming, welding, heat treatment and cleaning processes for the metal manufacturing of all containers designed to use liquid hydrogen and type 1, 2 and 3 containers designed to use compressed (gaseous) hydrogen

Reference to this Regulation and the container type

Container drawings shall show at least the following information:

Layout of cooling/heating system(s) including Nominal or Maximum Allowable Working Pressure (NAWP or MAWP) and operating temperatures …

Number of filling cycles or duty cycles as appropriate (1) : …

Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2) : …

Number of filling cycles or duty cycles as appropriate (1) : …

Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2) : …

Other adjustment possibilities: if so and which (description and drawings): …

Number of filling cycles or duty cycles as appropriate (1) : …

Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2) : …

Number of filling cycles or duty cycles as appropriate (1) : …

Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2) :

Number of filling cycles or duty cycles as appropriate (1) : …

Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2) : …

Number of filling cycles or duty cycles as appropriate (1) : …

Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2) :

Number of filling cycles or duty cycles as appropriate (1) : …

Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2) :

Number of filling cycles or duty cycles as appropriate (1) : …

Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2) : …

Number of filling cycles or duty cycles as appropriate: …

Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (2) : …

Number of filling cycles or duty cycles as appropriate (1) : …

Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2) : …

Number of filling cycles or duty cycles as appropriate (1) : …

Nominal working pressure(s) and if downstream of the first pressure regulator, maximum allowable working pressure(s) (1) (2) : …

Manufacturer's system code(s) (as marked on the system, or other means of identification) (1) : …

Name and address of the manufacturer(s) of the hydrogen system (1) : …

Hydrogen system designed to use liquid hydrogen / Hydrogen system designed to use compressed (gaseous) hydrogen / Hydrogen component designed to use liquid hydrogen / Hydrogen component designed to use compressed (gaseous) hydrogen (1) : …

Name and address of the manufacturer's representative (if any): …

Location and method of affixing of the EC type-approval mark(s):

Reference(s) or part number(s) of the component(s) in the system (1) :

If the systems or components have electronic controls, information concerning their performance shall be supplied.

The following information shall be supplied in triplicate and include a list of contents. Any drawings shall be supplied in appropriate scale and in sufficient detail on size A4 or on a folder of A4 format. Photographs, if any, shall show sufficient detail.

4.12.6. The pressure relief devices shall not leak at a rate exceeding 10 cm3/hour at any gas pressure between zero and set pressure minus 10 per cent.

4.12.5. Non-return valves if used as a safety device or refuelling connections or receptacles shall not leak at a rate exceeding 10 cm3/hour during the test.

4.12.4. A non-return valve, when in the closed position, shall not leak when subjected to any aerostatic pressure between 50 kPa and its Maximum Allowable Working Pressure (MAWP).

4.12.3. The seat of a shut-off valve, when in the closed position, shall not leak at a rate exceeding 10 cm3/hour at any gas pressure between zero and the Maximum Allowable Working Pressure (MAWP).

4.12.2. Seat leakage tests shall be conducted with the inlet of the sample valve connected to a source of gas pressure, the valve in the closed position, and with the outlet open. A positive shut-off valve and a pressure gauge having a pressure range of not less than 1,5 times and not more than twice the test pressure shall be installed in the pressure supply piping and the accuracy of the gauge shall be 1 per cent of the pressure range. The pressure gauge shall be installed between the positive shut-off valve and the sample under test. While under the applied test pressure corresponding to the Maximum Allowable Working Pressure (MAWP), observations for leakage shall be made with the open outlet submerged in water or by a flow meter installed on the inlet side of the valve under test. The flow meter shall be capable of indicating, for the test fluid employed, the maximum leakage flow rates permitted within an accuracy of +/- 1 per cent.

4.12.1. The seat leakage tests shall be carried out on samples which have previously been subjected to the external leakage test referred to in section 4.3.

4.11.2. The materials of the components in contact with cryogenic temperatures shall be compatible with cryogenic temperatures according to EN 1252-1.

4.11.1. The hydrogen compatibility shall be proved according to ISO 11114-4.

4.10.3. The appropriate test for external leakage, as referred to in section 4.3. shall be carried out immediately following the endurance test.

4.10.2. The pressure shall change from atmospheric pressure to the Maximum Allowable Working Pressure (MAWP) of the tank within less than five seconds, and after a time of at least five seconds, shall decrease to atmospheric pressure within less than five seconds.

4.10.1. Any flexible fuel line shall be capable of conforming to the applicable leakage test requirements referred to in section 4.3., after being subjected to 6 000 pressure cycles.

A non-metallic part containing hydrogen shall comply with the leakage tests referred to in sections 4.3. and 4.12. 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 Allowable Working Pressure (MAWP).

4.8.2. No cracking of the test piece is allowed.

4.8.1. The test shall be in compliance with ISO 1431-1. The test piece, which shall be stressed to 20 per cent elongation, shall be exposed to air at +40 °C with an ozone concentration of 50 parts per hundred million during 120 hours.

The test shall be carried out in compliance with ISO 188. The test piece shall be exposed to air at a temperature equal to the maximum operating temperature for 168 hours. The change in tensile strength shall not exceed +25 per cent. The change in ultimate elongation shall not exceed the following values:

4.6.2. A copper or brass hydrogen containing component shall comply with the leakage tests referred to in sections 4.3. and 4.12. and after being submitted to 24 hours immersion in ammonia according to ISO 6957 with all connections closed.

4.6.1. Metallic hydrogen components shall comply with the leakage tests referred to in sections 4.3. and 4.12. after being submitted to 144 hours salt spray test according to ISO 9227 with all connections closed.

4.5.1. The operational test shall be carried out in accordance with EN 13648-1 or EN 13648 2. The specific requirements of the standard are applicable.

4.4.6. The component shall be operated through 2 per cent of the total cycles at the minimum material temperature (according to section 1.3 of Part 1) but not less than the temperature of liquid nitrogen after sufficient conditioning time at this temperature to ensure thermal stability and at the MAWP of the component. The component shall comply with sections 4.3. and 4.12. at the appropriate minimum material temperature (according to section 1.3 of Part 1) at the completion of the low temperature cycles.

4.4.5. The component shall be operated through 2 per cent of the total cycles at the maximum material temperature (according to section 1.3 of Part 1) after sufficient conditioning time at this temperature to ensure thermal stability and at MAWP. The component shall comply with sections 4.3. and 4.12. at the appropriate maximum material temperature (according to section 1.3 of Part 1) at the completion of the high temperature cycles.

4.4.4. The component shall be operated through 96 per cent of the number of specified cycles at ambient temperature and at the MAWP of the component. During the off cycle the downstream pressure of the test fixture shall be allowed to decay to 50 per cent of the MAWP of the component.

4.4.3. The component shall be securely connected to a pressurised source of dry air or nitrogen and subjected to the number of cycles specified for that specific component in sections 3.1. to 3.7. of Part 3. A cycle shall consist of one opening and one closing of the component within a period of not less than 10 ± 2 seconds.

4.4.2. The appropriate tests for external leakage and seat leakage, as described in sections 4.3. and 4.12. shall be carried out immediately following the endurance test.

4.4.1. A hydrogen component shall be capable of conforming to the applicable leakage test requirements of sections 4.3. and 4.12., after being subjected to the number of operation cycles specified for that component in sections 3.1. to 3.7. of Part 3.

4.3.4. Throughout the test, the sample shall be tested for leakage, with a surface active agent without formation of bubbles or measured with a leakage rate less than 10 cm3/hour.

4.3.3. During this test the equipment under test shall be connected to a source of gas 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 shall be installed in the pressure supply piping and the accuracy of the gauge shall be 1 per cent of the pressure range. The pressure gauge shall be installed between the positive shut-off valve and the sample under test.

4.3.2.3. at the maximum operating temperature after sufficient conditioning time at this temperature to ensure thermal stability.

4.3.2.2. at the minimum operating temperature or at liquid nitrogen temperature after sufficient conditioning time at this temperature to ensure thermal stability;

The test shall be performed on the same equipment at the following conditions:

4.3.1. 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 section 4.4.3. at any gas pressure between zero and its Maximum Allowable Working Pressure (MAWP).

4.2.3. For components requiring a leakage test, this test shall be performed prior to the pressure test.

4.2.2. The pressure supply system shall be equipped with 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 and the accuracy of the gauge shall be 1 per cent of the pressure range.

4.2.1. A hydrogen containing component shall withstand without any visible evidence of leak or deformation a test pressure of 1,5 times its Maximum Allowable Working Pressure (MAWP) with the outlets of the high pressure part plugged. The pressure shall then be increased from 1,5 to 3 times the Maximum Allowable Working Pressure (MAWP). The component shall not show any visible evidence of rupture or cracks.

4.1.6. The different components shall be correctly dried before leak test.

4.1.5. All tests shall be performed at ambient temperature, unless otherwise stated.

4.1.4. The test period for leakage and pressure tests shall be not less than 3 minutes more than the response time of the sensor.

4.1.3. All test records shall indicate the type of test medium used, if applicable.

4.1.2. Water or another fluid may be used to obtain the required pressure for pressure test.

4.1.1. Leakage tests shall be conducted with pressurised gas such as air or nitrogen containing at least 10 per cent helium.

3.8.2. In case of power supply bushing to establish an isolated and tight electrical connection, the electric connection shall be of a hermetic sealed type.

the electric circuit insulation resistance (batteries and fuel cells excluded), shall exceed 1 kΩ for each volt of the nominal voltage.

the electrical system of the electrically operated device shall be insulated from the body of the vehicle;

electrically operated devices containing hydrogen shall be insulated in a manner that no current passes through hydrogen containing parts;

section 4.6, only for metallic parts, only for equipment outside of the gas tight housing

3.7.1.3.2. If operated with cryogenic temperature: lowest operating temperature: – 253 °C, maximum temperature: +85 °C or + 120 °C as given in section 1.3 of Part 1.

3.7.1.3.1. If operated with ambient temperature: according to section 1.3 of Part 1.

3.7.1.2. Maximum Allowable Working Pressure (MAWP): 1,5 × Maximum Allowable Working Pressure (MAWP) of the inner tank or maximum pressure the component is subjected to.

3.7.1.1. The design, manufacturing and control of the cryogenic flexible fuel lines shall be in accordance with EN 12434.

section 4.6, only for metallic parts, only for equipment outside of the gas tight housing

section 4.3, only for equipment directly in contact with hydrogen

section 4.2, only for equipment directly in contact with hydrogen

3.6.1.2.2. If operated with cryogenic temperature: lowest operating temperature: – 253 °C, maximum temperature: +85 °C or + 120 °C as given in section 1.3 of Part 1.

3.6.1.2.1. If operated with ambient temperature: according to section 1.3 of Part 1.

3.6.1.1. Maximum Allowable Working Pressure (MAWP): 1,5 × Maximum Allowable Working Pressure (MAWP) of the inner tank or maximum pressure the component is subjected to.

section 4.6, only for metallic parts, only for equipment outside of the gas tight housing

3.5.1.2.2. Internal temperature: at least as given in section 1.3 of Part 1.

3.5.1.1. Maximum Allowable Working Pressure (MAWP): 1,5 × Maximum Allowable Working Pressure (MAWP) of the inner tank or maximum pressure the component is subjected to.

3.4.2.1. Maximum Allowable Working Pressure (MAWP): 1,5 × Maximum Allowable Working Pressure (MAWP) of the inner tank or maximum pressure the component is subjected to.

3.4.2. Provisions regarding the approval of refuelling connections or receptacles

3.4.1. The refuelling connections or receptacles shall be protected against contamination.

3.3.4.4. The manufacturing and mounting of the heat exchanger shall be certified according to sections 4.3. to 4.5 of Part 2.

3.3.4.1. Maximum Allowable Working Pressure (MAWP): 1,5 × Maximum Allowable Working Pressure (MAWP) of the inner tank or maximum pressure the component is subjected to.

3.3.3. A safety system shall be provided to: prevent failure of the heat exchanger; and prevent any cryogenic liquid or gas from entering the other circuit and the system located downstream of it, if it has not been designed for this.

3.3.2. The exhaust gases from the propulsion system shall not under any circumstances be used directly in the heat exchanger.

3.3.1. Notwithstanding the provision of section 2.1. the Maximum Allowable Working Pressure (MAWP) of the heat exchanger shall be the highest Maximum Allowable Working Pressure (MAWP) of the different circuits.

section 4.6, only for metallic parts, only for equipment outside of the gas tight housing

(with 6 000 operation cycles for manual valves with 20 000 operation cycles for automatic valves)

–40 °C to +85 °C for valves after the heat exchanger

– 253 °C to +85 °C for valves before the heat exchanger

3.2.1.2. Maximum Allowable Working Pressure (MAWP): 1,5 × Maximum Allowable Working Pressure (MAWP) of the inner tank or maximum pressure the valve is subjected to.

3.2.1.1. The design, manufacturing and checking of the cryogenic hydrogen valves shall be in accordance with EN 13648-1 and EN 13648-2.

3.1.4.2. The lines before and behind the pressure relief devices shall not impede their function and shall be compatible with the criteria defined in sections 3.1.1. to 3.1.3.

3.1.4.1. No isolating device shall be installed between the protected component and the pressure relief device.

section 4.6, only for metallic parts, only for equipment outside of the gas tight housing

3.1.3.4.3. Pressure relief devices for components other than the tank: according to section 3.1.2.

3.1.3.4.2. Secondary device of the inner tank: according to section 3.1.1.2.

3.1.3.4.1. Primary devices of the inner tank: according to section 3.1.1.1.

3.1.3.3. Maximum Allowable Working Pressure (MAWP): 1,5 × Maximum Allowable Working Pressure (MAWP) of the inner tank or maximum pressure the component is subjected to.

3.1.3.2. In case of boil off system in parallel of the primary safety device, then the safety valve shall be a category B safety device otherwise it shall be a category A safety device according to EN 13648.

3.1.3.1. The design, manufacturing and control of the pressure relief devices shall be in accordance with EN 13648-1 and EN 13648-2.

3.1.2.4. Pressure relief valves shall, after discharge, close at a pressure higher than 90 per cent of the set pressure of the pressure relief valve. They shall remain closed at all lower pressures.

3.1.2.3. The rating of pressure relief devices downstream of the pressure regulator(s) shall not exceed the Maximum Allowable Working Pressure (MAWP) of the components downstream of the pressure regulator.

3.1.2.2. Upstream of the first pressure regulator the set pressure of the safety device which prevents over-pressurisation shall not exceed the Maximum Allowable Working Pressure (MAWP) of the lines and shall not be less than 120 per cent of the Maximum Allowable Working Pressure (MAWP) of the tank, to prevent such valves opening instead of the pressure relief devices for the inner tank.

3.1.2.1. Whenever there is a risk of cryogenic liquid or vapour becoming trapped between two items of equipment on a line, a pressure relief device or a measure ensuring an equivalent level of safety shall be provided.

3.1.1.7. Pressure relief valves shall be installed on the gaseous fraction area of the hydrogen tank.

3.1.1.6. Pressure relief valves shall, after discharge, close at a pressure higher than 90 per cent of the set pressure of the pressure relief valve. They shall remain closed at all lower pressures.

3.1.1.5. The rating of the pressure relief devices shall be clearly marked. Tampering with the devices shall be prevented by means of a lead seal or equivalent system.

3.1.1.4. The two devices referred to in sections 3.1.1.1. and 3.1.1.2. may be connected to the inner tank by the same fuel line.

3.1.1.3. The sizing of the safety devices shall be done in accordance with EN 13648-3.

3.1.1.2. The secondary pressure relief device for the inner tank shall be installed to ensure that the pressure in the tank cannot under any circumstances exceed the permissible fault range of the inner tank. In the case of steel inner tanks, the secondary pressure relief device shall limit the pressure in the tank to 136 per cent of the Maximum Allowable Working Pressure (MAWP) of the inner tank, if a safety valve is used as secondary pressure relief device. In case of steel inner tanks, the secondary pressure relief device shall limit the pressure in the tank to 150 per cent of the Maximum Allowable Working Pressure (MAWP) of the inner tank, if a burst disk is used outside the vacuum area as secondary pressure relief device. In case of steel inner tanks, the secondary pressure relief device shall limit the pressure in the tank to 150 per cent of the Maximum Allowable Working Pressure plus 0,1 MPa (MAWP + 0,1 MPa) of the inner tank, if a burst disk is used inside the vacuum area as secondary pressure relief device. For other materials, an equivalent level of safety shall be demonstrated. The secondary pressure relief device shall not operate below 110 per cent of the set pressure of the primary pressure relief device.

3.1.1.1. The primary pressure relief device for the inner tank shall limit the pressure inside the tank to not more than 110 per cent of the Maximum Allowable Working Pressure (MAWP), even in case of a sudden vacuum loss. This device shall be a safety valve or equivalent and shall be connected directly to the gaseous part under normal operating conditions.

2.4. The insulation of the components shall prevent liquefaction of the air in contact with the outer surfaces, unless a system is provided for collecting and vaporising the liquefied air. Then the materials of the components nearby shall be compatible with an atmosphere enriched with oxygen according to EN 1797.

2.3. Components downstream of pressure regulator(s) shall be protected against over-pressurisation and shall be designed for at least 1,5 times the outlet pressure (Maximum Allowable Working Pressure (MAWP)) of the first pressure regulator upstream.

2.2. The hydrogen system upstream of the first pressure regulator, excluding the hydrogen container, shall have a Maximum Allowable Working Pressure (MAWP) equal to the maximum pressure the component is subjected to but at least 1,5 times the set pressure of the primary safety relief device of the inner tank and a coefficient of safety not less than that of the inner tank.

2.1. Materials used in hydrogen components shall be compatible with hydrogen in accordance with section 4.11.

This Part sets out the requirements and test procedures for hydrogen components other than containers designed to use liquid hydrogen.

Requirements for hydrogen components other than containers designed to use liquid hydrogen

The test conditions and the ten maximum level measured by the added system shall be written in a test certificate signed by the manufacturer and the technical service.

6.3.9.2.5. The tank shall be completely filled 10 times with liquid hydrogen at equilibrium with its vapour. Between each filling at least a quarter of the liquid hydrogen of the tank shall be emptied.

6.3.9.2.4. The mass of hydrogen or the mass flow rate at the inlet and the outlet of the tank shall be measured with an accuracy better than 1 per cent of the maximum filling mass of the tested container

6.3.9.2.3. The tank shall already be cooled down and the inner tank shall be at the same temperature as the liquid hydrogen. The tank shall have contained during the previous 24 hours a volume of liquid hydrogen at least equal to half of the water volume of the inner tank.

6.3.9.2.2. Its manufacturing shall be completely finished and it shall be fitted with all its equipment and particularly the level gauge.

6.3.9.2.1. The tested tank shall be representative of the design and the manufacturing of the type to be approved.

During all the tests necessary for approval, the filling process shall not lead to any pressure relief device coming into operation irrespective of time passed during/after the filling process. The filling process shall not lead to operating conditions the BMS (boil-off management system) is not designed for and therefore cannot handle.

The test conditions and the maximum pressure reached within the tank during the test shall be recorded in a test certificate signed by the manufacturer and the technical service.

6.3.8.2.3.4. Once the safety device opens, the test shall continue until the blow off of the safety device has finished. During the test the tank shall not burst and the pressure inside the inner tank shall not exceed the permissible fault range of the inner tank. In the case of steel inner tanks, the tank pressure shall not exceed 136 per cent of the Maximum Allowable Working Pressure (MAWP) of the inner tank. For other materials, an equivalent level of safety shall be applied.

6.3.8.2.3.3. The pressure of the tank at the beginning of the test shall be between 0 MPa and 0,01 MPa at the boiling point of hydrogen in the inner tank.

6.3.8.2.3.2. A fire shall burn 0,1 m underneath the tank. The length and the width of the fire shall exceed the plan dimensions of the container by 0,1 m. The temperature of the fire shall be at least 590 °C. The fire shall continue to burn for the duration of the test.

6.3.8.2.3.1. The tank shall be filled with liquid hydrogen so that the quantity of liquid hydrogen measured by the mass measurement system shall be half of the maximum allowed quantity that may be contained in the inner tank.

The tank shall already be cooled down and the inner tank shall be at the same temperature as the liquid hydrogen. The tank shall have contained during the previous 24 hours a volume of liquid hydrogen at least equal to half of the water volume of the inner tank.

6.3.8.2.2. Its manufacturing shall be completely finished and it shall be mounted with all its equipment.

6.3.8.2.1. The tested tank shall be representative of the design and the manufacturing of the type to be approved.

The secondary pressure relief device shall not operate below 110 per cent of the set pressure of the primary pressure relief device.

For other materials, an equivalent level of safety shall be demonstrated.

In case of steel inner tanks, the secondary pressure relief device shall limit the pressure inside the tank to 150 per cent of the Maximum Allowable Working Pressure plus 0,1 MPa (MAWP + 0,1 MPa) of the inner tank, if a burst disk is used inside the vacuum area as secondary pressure relief device.

In case of steel inner tanks, the secondary pressure relief device shall limit the pressure inside the tank to 150 per cent of the Maximum Allowable Working Pressure (MAWP) of the inner tank, if a burst disk is used outside the vacuum area as secondary pressure relief device.

6.3.8.1.1. The tank shall not burst and the pressure inside the inner tank shall not exceed the permissible fault range of the inner tank. In case of steel inner tanks, the secondary pressure relief device shall limit the pressure inside the tank to 136 per cent of the Maximum Allowable Working Pressure (MAWP) of the inner tank, if a safety valve is used as secondary pressure relief device.

The test conditions and the bursting pressure shall be written in a test certificate signed by the manufacturer and the technical service.

6.3.7.2.6. The pressure shall be recorded or written during the entire test.

6.3.7.2.5. A system shall enable to look at possible deformations.

6.3.7.2.4. The tank shall be filled with water. The pressure shall be increased at a constant rate not exceeding 0,5 MPa/min until burst. When the Maximum Allowable Working Pressure (MAWP) is reached there shall be a wait period of at least ten minutes at constant pressure so that the deformation of the tank shall be checked.

6.3.7.2.3. The tube and piping may be modified to enable the test (purge of dead volume, introduction of the liquid, closing of non-used pipes, etc.)

6.3.7.2.1. The tested tank shall be representative of the design and the manufacturing of the type to be approved.

6.3.7.1.2. Hydrogen containers made from materials other than steel shall be demonstrated to perform as safely as containers complying with the requirements set out in points 6.3.7.1.1. and 6.3.7.1.2.

or the Maximum Allowable Working Pressure (MAWP) (in MPa) plus 0,1 MPa multiplied by 1,5 and multiplied by Rm/Rp, where Rm means minimum ultimate tensile strength and Rp means minimum yield strength.

either the Maximum Allowable Working Pressure (MAWP) (in MPa) plus 0,1 MPa multiplied by 3,25;

6.3.7.1.1. The burst pressure shall be at least equal to the burst pressure used for the mechanical calculations. For steel tanks that is:

The burst test shall be performed on one sample of the inner tank, not integrated in its outer jacket and not insulated.

The marking shall be verified in accordance with section 5.5.

The welding seams and the inner and outer surfaces of the inner and outer jackets of the container shall be inspected visually. The surfaces shall not show any critical damages or defaults.

The tests shall be performed according to EN 1251-2.

departure from a straight line of the inner and outer jacket according to EN 1251-2, 5.4

for cylindrical container(s) roundness of the inner tank according to EN 1251-2:2000, 5.4

The following dimensions shall be verified:

After final assembly the hydrogen container shall be leak tested with a gas mixture containing a minimum of 10 per cent of helium

6.3.1.9. A test report shall be drawn up and the inner tank shall be marked by the inspection departments if accepted.

6.3.1.8. In case of hydraulic test, upon completion of this test, the container shall be emptied and dried until the dew point inside the container is –40 °C according to EN 12300.

6.3.1.7. Any inner tank tested which does not pass the test because of leakage may be accepted after repair and retesting.

6.3.1.6. Any inner tank tested which does not pass the test because of permanent deformation shall be rejected and shall not be repaired.

6.3.1.5. After the test the inner tank must not show any signs of visible permanent deformation or visible leaks.

6.3.1.4. The inner tank must remain under the test pressure at least for 10 minutes to establish that the pressure is not reducing.

6.3.1.3. The pressure in the inner tank shall be increased at a constant rate until the test pressure is reached.

6.3.1.2. The pressure test shall be performed before the outer jacket is mounted.

with MAWP being the Maximum Allowable Working Pressure of the inner tank in MPa.

6.3.1.1. The inner tank and the pipe work situated between the inner tank and the outer jacket shall withstand an inner pressure test at room temperature any suitable media, according to the following requirements.

The tests and inspections according to sections 6.3.1. to 6.3.6. shall be performed on each container.

For the approval, the technical service shall perform the tests and inspections according to sections 6.3.1. to 6.3.6. on two samples of containers. The samples shall be provided in the applicable state necessary for the inspections. For the approval, samples of the container shall be subjected to the tests according to sections 6.3.7. to 6.3.9. and shall be witnessed by the technical service.

Inspection openings are not required in the inner or outer jacket.

5.5.2. The marking method shall not cause localised stress peaks in the structure of the inner tank or the outer jacket.

the identification plate shall be legible while installed.

an identification plate with the following information:

an allowed orientation of the tank in the vehicle;

a label as set out in section 3.1 of Annex V;

the name and address of inner tank manufacturer,

In addition to the EC component type-approval mark set out in Part 3 of Annex II, every container shall also bear a marking with the following data clearly legible:

5.4.2. The filling process shall not lead to any pressure relief device coming into operation irrespective of time passed during/after the filling process. The filling process shall not lead to operating conditions the BMS (boil-off management system) is not designed for and therefore cannot handle.

5.4.1. A system shall be provided for preventing the container from being overfilled. This system may work in conjunction with the refuelling station. This system shall bear a permanent marking, indicating the container-type for which it has been designed and if applicable the mounting position and orientation.

5.3.2. If the system comprises a float, the latter shall withstand an outside pressure greater than the Maximum Allowable Working Pressure (MAWP) of the inner tank with a minimum coefficient of safety of 2 with respect to the buckling failure criteria.

5.3.1. A measuring gauge in the driver's compartment shall indicate the level of liquid in the container with an accuracy of +/- 10 per cent.

5.2.1. Under no circumstances may ice be allowed to form on the outer wall of the container under normal operating conditions. At the area of pressure relief pipe, local ice formation is allowed on the outside of the pipe.

The outer jacket shall be protected by means of a device preventing bursting of the outer jacket or collapsing of the inner tank.

4.8. The container shall be cleaned and dried before operation according to EN 12300.

4.7. The equipment of the container shall be mounted in a way that the system and its components function in a correct and safe way and are gas tight.

4.6. The number of joints should be minimised. Joints shall not be permitted within the void between the inner tank and the outer jacket unless they are welded or glued.

4.5. The inspections and the testing of the internal pipe work between the inner tank and the outer jacket: all welded joints of the pipe work shall be subject to 100 per cent non-destructive inspection, wherever possible by radiographic inspection, alternatively ultrasonic test, liquid penetrant testing, helium leakage test, etc.

4.4. Manufacturing operations (e.g. forming and heat treatment, welding) shall be carried out according to EN 1251-2.

4.3. Welders shall be approved by the technical service according to EN 287-1:1992/A1:1997, EN 287-2:1992/A1:1997 and for automatic welding operators in accordance with EN 1418:1997.

4.2. The welding process shall be approved by the technical service in accordance with EN 288-3:1992/A1:1997, EN 288-4:1992/A1:1997 and EN 288-8:1995.

4.1. Manufacturers of welded containers shall have a welding quality system in operation, taking into account the quality requirements for welding in accordance with EN 729-2:1994 or EN 729-3:1994.

The design of the outer jacket shall be done according to the design rules of EN 1251-2.

The design of the inner tank shall be done according to the design rules of EN 1251-2.

3.3.5. Material sheets shall be marked at least with:

3.3.4. The manufacturer shall make available to the technical service the results of metallurgical and mechanical tests and analyses of parent and filler materials carried out on welds.

3.3.3. The technical service may carry out analyses and examinations. These examinations shall be carried out either on specimens taken from the materials as supplied to the manufacturer of the container or on the finished containers.

3.3.2. The manufacturer shall obtain and provide chemical cast analysis and mechanical properties certificates of the material in respect of the steels or other materials used in the construction of the parts subject to pressure. In case of metallic materials the certificate must be at least type 3.1 according to EN 10204 or equivalent. In case of non-metallic materials the certificate must be of equivalent type.

3.3.1. The filler materials shall be compatible with the parent material so as to form welds with properties equivalent to those specified for the parent material for all temperatures that the material may encounter.

3.2.3. A corrosion allowance is not required for the inner tank. A corrosion allowance is not required on other surfaces if they are adequately protected against corrosion.

3.2.2. The materials used for the outer jacket shall ensure the integrity of the insulation system, and their elongation at fracture in a tensile test shall be at least 12 per cent at liquid nitrogen temperature.

3.2.1. Materials used at low temperatures shall follow the toughness requirements of EN 1252-1. For non-metallic materials low temperature suitability shall be validated by an experimental method, taking into account service conditions.

the finished products which are used for pressurised components and are in contact with hydrogen resist the thermal, chemical and mechanical stresses that they may be subjected to. In particular, the materials of the components in contact with cryogenic temperatures shall be compatible with cryogenic temperatures according to EN 1252-1.

3.1. The materials shall be composed, manufactured and further treated in a manner that:

any other media the parts are in contact with (i.e. coolant etc.).

the atmosphere, if the parts are in contact with it;

hydrogen, if the parts are in contact with it;

2.4.1. The materials of the container and its equipment shall be compatible with:

2.3.3. The thermal stresses by operating conditions like filling or withdrawal or during the cooling down processes shall be considered.

For all other equipment which is not mentioned under section 2.3.1. the design temperature is the lowest respectively the highest possible operating temperature set out in section 1.3. of Part 1.

The design temperature of the inner tank and the outer jacket shall be 20 °C.

2.2.6. The proof of the dimensioning of the supports of the container can be done either by calculation or by experiment.

2.2.5. The requirements of sections 2.2.3. and 2.2.4. do not apply if it can be demonstrated that the tank may support the accelerations referred to in section 2.3 of Part 1 without any leak on the inner tank and all the different pipes upstream of the automatic safety devices, shut off valves and/or non-return valves.

The inner supports of the full container shall resist the accelerations referred to in section 2.3 of Part 1 without rupture, in which case the allowable stress in the support elements calculated according to linear stress model shall not exceed:

The outer supports of the full container shall resist the accelerations referred to in section 2.3 of Part 1 without rupture, in which case the allowable stress in the support elements calculated according to linear stress model shall not exceed:

2.2.2.2. The outer jacket shall resist an outer pressure of 0,1 MPa.

2.2.2.1. The outer jacket shall resist the Maximum Allowable Working Pressure (MAWP), which is the set pressure of its safety device.

If an operating mode of the inner tank and its equipment under vacuum is possible, the inner tank and its equipment shall resist an outer pressure of 0,1 MPa.

with MAWP being the Maximum Allowable Working Pressure of the inner tank in MPa

The inner tank shall resist the test pressure Ptest:

The parts of the container shall withstand the following mechanical stresses:

2.1. The design validation of the container by calculation shall be done in accordance with EN 1251-2.

This Part sets out the requirements and test procedures for hydrogen containers designed to use liquid hydrogen.

11.2. The inspection shall be performed by a technical service, in accordance with the manufacturers specifications set out in Part 3 of Annex I.

11.1. Each hydrogen system shall be inspected at least every 48 months after the date of its entry into service, and at the time of any re-installation.

11. Requirements for the inspection of the hydrogen system

10.2. If the safety-instrumented systems under section 10.1. are fail-safe or self-monitoring electronic systems, the special requirements of Annex VI to this Regulation shall be applied.

9.4. Failure of the heating circuit of the heat exchanger shall not cause leakage from the hydrogen system.

9.3. Flammable materials used in the vehicle shall be protected from liquefied air that may condense on un-insulated elements of the fuel system.

9.2. The passenger compartment, the luggage compartment and all safety-critical components of the vehicle (e.g. the brake system, electrical insulation) shall be protected against adverse temperature effects due to the cryogenic fuel. Possible leakage of the cryogenic fuel shall be considered when assessing the protection that is required.

9.1. All pressure relief devices and vent line(s) shall be protected against vandalism so far as reasonably practicable.

8.3. At start-up and during the operation of the vehicle, a warning system shall be activated to warn the driver in the event of the boil off management system failure.

8.2. The boil-off management system shall be designed to accept the boil-off rate of the container(s) under normal operating conditions.

7.2. Power supply connections shall be tight against the ingress of hydrogen where hydrogen components are present or hydrogen leaks are possible.

7.1. The electrical components of the hydrogen system shall be protected against overloads.

6.5. It shall be ensured that the propulsion system cannot be operated and the vehicle cannot move while the refuelling connection or receptacle is connected to the filling station.

6.4. The refuelling connection or receptacle shall have an isolating device according to section 3.1.2.

6.3. The refuelling line shall be secured at the container as described in section 3.1.1.

6.2. The refuelling connection or receptacle shall not be installed in the engine compartment, passenger compartment or in any other unventilated compartment.

6.1. The refuelling connection or receptacle shall be secured against maladjustment and shall be protected from dirt and water. It shall be safe against handing errors.

5.4. In a passenger or enclosed luggage compartment, the fuel lines shall be no longer than reasonably required.

5.3. Any joints shall be made in locations where access is possible for inspection and leak testing.

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

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

4.5. At penetration through the vehicle body or other hydrogen components, the fuel lines shall be fitted with grommets or other protective material.

4.4. Rigid and flexible fuel lines shall be routed to reasonably minimise exposure to accidental damage whether inside e.g. due to placing or movement of luggage or other loads, or outside the vehicle, e.g. due to rough ground or vehicle jacks etc.

4.3. At the fixing points the fuel lines, flexible or rigid, shall be fitted in such a way that they cannot make a metal to metal contact to prevent galvanic and crevice corrosion.

4.2. Flexible fuel lines shall be secured such that they shall not be subjected to torsional stresses, abrasion is avoided and cannot be squeezed in normal use.

4.1. Rigid fuel lines shall be secured such that they shall not be subjected to abrasion, critical vibration and/or other stresses.

3.3.7. Any connecting system shall be secured by clamps, or other means, to the gas tight housing and the lead-through to ensure that a gas tight joint is formed.

3.3.6. This housing shall be for test purposes hermetically sealed and shall be gas tight at a pressure of 0,5 kPa, i.e. bubble-free for 1 minute and without any permanent deformation.

3.3.5. Any connecting system and lead-through in the body of the vehicle for ventilation of the gas tight housing shall have at least the same cross sectional area as the tube of the pressure relief device.

3.3.4. There shall be no unprotected ignition sources inside the gas tight housing.

3.3.3. The ventilation opening of the gas tight housing shall be at the highest point of the housing and shall not discharge at a heat source such as the exhaust. Additionally it shall discharge such that hydrogen cannot enter the inside of the vehicle and/or accumulate in an enclosed or partially enclosed space.

3.3.2. The gas tight housing shall be vented to the atmosphere.

3.3.1. All non-welded connections of hydrogen-carrying components and the hydrogen components which can leak, that are mounted within the passenger or luggage compartment or other non-ventilated compartment, shall be enclosed by a gas tight housing.

In the case of steel inner tanks, the lower limit of the impermissible fault range corresponds to a pressure higher than 136 per cent of the Maximum Allowable Working Pressure (MAWP) of the inner tank if a safety valve is used as secondary pressure relief device. In case of steel inner tanks, the lower limit of the impermissible fault range corresponds to a pressure higher than 150 per cent of the Maximum Allowable Working Pressure (MAWP) of the inner tank if a burst disk is used as secondary pressure relief device. For other materials an equivalent level of safety is to be applied. The impermissible fault range shall be the pressure at which plastic deformation or bursting of the inner tank occurs as shown in Figure 3.2.

3.2.2. In the case of inner tanks, the normal operating range of the inner tank pressure is between 0 MPa and the set pressure of the primary safety relief device which is lower or equal to the Maximum Allowable Working Pressure (MAWP) of the inner tank.

3.2.1. The pressure triggered pressure relief devices shall be fitted to the hydrogen container(s) in such a manner that they must discharge into an atmospheric outlet line that vents outside the vehicle. They shall not discharge at a heat source such as the exhaust. Additionally they shall discharge such that hydrogen cannot enter the inside of the vehicle and/or accumulate in an enclosed space. Additionally the first pressure relief device shall not discharge into a partially enclosed space. In case the secondary pressure relief device is a burst disc and is installed within the inner tank, an appropriate exhaust vent in the outer jacket is required.

3.1.5. When another hydrogen conversion system is switched off, irrespective of the position of the activation switch, the fuel supply to the respective hydrogen conversion system shall be switched off and remain closed until the respective hydrogen conversion system is required to operate.

3.1.3. In the event that the container is displaced, the first isolating device and, if applicable, the line connecting it to the container shall be protected in such a manner that the shut-off function remains operational and the connection between the device and the container cannot be ruptured.

3.1.2. Refuelling connections or receptacles shall be used in compliance wit section 4. of Annex VI to Regulation (EC) No 79/2009.

3.1.1. Automatic shut-off valves shall be used in compliance with section 6. of Annex VI to Regulation (EC) No 79/2009, except for the boil-off management system and shall be idle closed.

2.4. The provisions of section 2.3 shall not apply if the vehicle is approved according to Directives 96/27/EC and 96/79/EC of the European Parliament and of the Council (1) (2) .

The hydrogen container(s) including the safety devices affixed at it must be mounted and fixed so that the following accelerations can be absorbed without breaking of the fixation or loosening of the container(s) (demonstrated by testing or calculation). The mass used shall be representative for a fully equipped and filled container or container assembly.

2.2. When the vehicle is ready for use the lowest part of the hydrogen container shall not reduce the ground clearance of the vehicle. This shall not apply if the hydrogen container is adequately protected, at the front and the sides, and no part of the hydrogen container is located lower than this protective structure.

2.1. The container can be integrated into the vehicle design to provide complementary functions. In such cases the container shall be designed to fulfil the integrated function requirements and the container requirements set out in Part 2.

1.5. In the event of hydrogen leakage or venting, hydrogen shall not be allowed to accumulate in enclosed or semi-enclosed spaces of the vehicle.

1.4. Appropriate automatic measures shall be adopted in coordination with the refuelling station to ensure that no uncontrolled hydrogen release occurs during the filling procedure.

1.2. The hydrogen system(s) shall show no leaks other than the boil-off at Maximum Allowable Working Pressure (MAWP), i.e. stay bubble-free if using leak-detecting spray.

1.1. All hydrogen components and systems shall be installed on the vehicle and connected in accordance with best practice.

Requirements for the installation of hydrogen components and systems designed to use liquid hydrogen on hydrogen powered vehicles

2.1. The materials used in a hydrogen component or system shall be compatible with hydrogen in its liquid and/or gaseous state according to section 4.11. of Part 3.

This Annex sets out the requirements and test procedures for hydrogen components and systems designed to use liquid hydrogen and their installation on hydrogen powered vehicles.

Requirements for hydrogen components and systems designed to use liquid hydrogen and their installation on hydrogen powered vehicles

ANNEX IV

Requirements for hydrogen components and systems designed to use compressed (gaseous) hydrogen and their installation on hydrogen powered vehicles

1. INTRODUCTION

This Annex sets out the requirements and test procedures for hydrogen components and systems designed to use compressed (gaseous) hydrogen.

2. GENERAL REQUIREMENTS

2.1. The number of hydrogen components, connections and the length of lines shall be kept to the minimum compatible with safety and the correct functioning of the hydrogen system.

2.2. The manufacturer shall ensure that the materials used in a hydrogen component or system are compatible with hydrogen and expected additives and production contaminants and expected temperatures and pressures.

2.3. Material compatibility with the service conditions defined in section 2.7. shall be demonstrated by the material tests in Parts 2 and 3.

2.4. Pressure classification

Hydrogen components shall be classified with regard to their nominal working pressure and function in accordance with points (2), (3) and (4) of Article 1.

2.5. The manufacturer shall ensure that the temperature range is in accordance with section 2.7.5.

2.6. The documentation and test reports shall be sufficiently detailed to enable an independent third party test facility to reproduce the appropriate type-approval tests and test results.

2.7. Service conditions

The service life of hydrogen containers shall be specified by the manufacturer and may vary with different applications, however, it shall not exceed 20 years.

2.7.1. Service life

The service life of hydrogen containers shall be specified by the manufacturer and may vary with different applications, however, it shall not exceed 20 years.

2.7.2. Working pressure

The vehicle manufacturer shall specify the nominal working pressure(s) of the hydrogen components and system. For the components downstream of the first pressure regulator, the MAWP(s) shall also be specified.

The MAWP(s) shall be equal to or shall exceed the set pressure of the overpressure protection specified in section 1.8. of Part 1.

2.7.3. External surfaces

The effects on external surfaces of the hydrogen components in their installed position shall be considered in relation to the following:

(a) Water, either by intermittent immersion or road spray;

(b) Salt, due to the operation of the vehicle near the ocean or where ice-melting salt is used;

(c) Ultra-violet radiation and heat radiation from sunlight;

(d) Impact of gravel;

(e) Solvents, acids and alkalis, fertilisers;

(f) Automotive fluids, including gasoline, hydraulic fluids, battery acid, glycol and oils;

(g) Exhaust gases.

2.7.4. Gas Composition

Compressed hydrogen gas used for testing shall comply with, or be of greater purity than, the Type 1, Grade A gas composition specified in ISO/TS 14687-2.

2.7.5. Temperatures

2.7.5.1. Material temperatures

The normal operating temperature range for materials used in hydrogen components shall be –40 °C to +85 °C except if:

(a) the vehicle manufacturer specifies a lower temperature than –40 °C;

(b) hydrogen components are situated either in an internal combustion engine compartment or directly exposed to the operating temperature of an internal combustion engine, for which the temperature range shall be –40 °C to + 120 °C.

2.7.5.2. Gas Temperatures

The average gas temperature shall be between –40 °C to +85 °C in normal conditions including filling and discharging, unless a lower temperature than –40 °C is specified by the vehicle manufacturer.

2.7.6. Filling cycles

This section is only applicable to Class 0 hydrogen components.

2.7.6.1. General

The number of filling cycles for the hydrogen components shall be 5 000 cycles except as permitted in sections 2.7.6.2. and 2.7.6.3.

2.7.6.2. Number of filling cycles if usage monitoring and control system is installed

Provided that a usage monitoring and control system is installed as part of the hydrogen system, the number of filling cycles for hydrogen components shall be specified by the vehicle manufacturer and may be less than 5 000 cycles, but not less than 1 000 cycles and may vary with different applications based on the design lifetime mileage of the vehicle and range with maximum fuel capacity.

The usage monitoring and control system shall prevent any further use of the vehicle when the specified number of filling cycles is exceeded, until the hydrogen components that have exceeded that value are replaced with new hydrogen components.

The safety concept of the usage monitoring and control system shall be approved in accordance with Annex VI.

2.7.6.3. Reduced number of filling cycles

The vehicle manufacturer may specify a reduced number of filling cycles for hydrogen components, calculated by applying the following formula:

Number of filling cycles based on 20 years service life: 5 000

Design service life: x years; x ≥ 1

Reduced number of filling cycles: 1 000 + 200*x

The hydrogen components shall be replaced before exceeding their specified service life.

2.7.7. Duty cycles

2.7.7.1. General

The number of duty cycles for hydrogen components shall be 50 000 cycles except as permitted in sections 2.7.7.2. and 2.7.7.3.

2.7.7.2. Number of duty cycles if usage monitoring and control system is installed

Provided that a usage monitoring and control system is installed as part of the hydrogen system, the number of duty cycles for hydrogen components may be reduced to less than 50 000 cycles, but not less than 10 000 cycles by the vehicle manufacturer based on the design lifetime of the component.

The usage monitoring and control system shall prevent any further use of the vehicle when the specified number of duty cycles is exceeded, until the hydrogen components that have exceeded that value are replaced with new hydrogen components.

The safety concept of the usage monitoring and control system shall be approved in accordance with Annex VI.

2.7.7.3. Reduced number of duty cycles

The vehicle manufacturer may specify a reduced number of duty cycles for each hydrogen component, calculated by applying the following formula:

Number of duty cycles based on 20 years service life: 50 000

Design service life: x years; x ≥ 1

Reduced number of duty cycles:

10 000 + 2 000*x

The hydrogen components shall be replaced before exceeding their specified service life.

PART 1

Requirements for the installation of hydrogen components and systems designed to use compressed (gaseous) hydrogen on hydrogen powered vehicles

1. GENERAL REQUIREMENTS

1.1. Reasonable precautions shall be taken to avoid failure of other circuits affecting the hydrogen system.

1.2. The hydrogen system shall be pressurised to nominal working pressure using 100 per cent hydrogen and tested for leakage, excluding the container, with a surface active agent without formation of bubbles for three minutes, or by using a demonstrated equivalent method.

1.3. In the event of hydrogen leakage or venting, hydrogen shall not be allowed to accumulate in enclosed or semi-enclosed spaces.

1.4. Hydrogen components that could leak hydrogen and that are mounted within the passenger or luggage compartment or other non-ventilated compartment shall be enclosed by a gas tight housing in accordance with section 10 or by an equivalent solution.

1.5. A minimum pressure of 0,2 MPa shall be maintained in the container or container assembly at ambient temperature.

1.6. All pressure relief devices, other safety components and vent lines shall be protected against unauthorised interference so far as reasonably practicable.

1.7. If the activation of the automatic valve fails, the valve shall switch to the safest mode of operation for the particular application.

1.8. The hydrogen system downstream of a pressure regulator shall be protected against overpressure due to the possible failure of the pressure regulator. If an overpressure protection device is used, the set pressure of such a device shall be lower than or equal to the MAWP for the appropriate section of the hydrogen system.

1.9. A system shall be provided to detect failure in either circuit of a heat exchanger and prevent hydrogen from entering the other circuit(s), if the interface(s) is not able to withstand loss of pressure in either circuit.

2. INSTALLATION OF A CONTAINER ON-BOARD A VEHICLE

2.1. A container or container assembly can fulfil integrated functions of the vehicle. A container or container assembly shall be designed to fulfil the integrated function requirements and the container requirements set out in Part 2.

A container or container assembly including safety devices shall be mounted and fixed so that the following accelerations can be absorbed without breaking of the fixation or loosening of the container(s) (demonstrated by testing or calculation). The mass used shall be representative for a fully equipped and filled container or container assembly.

Vehicles of categories M1 and N1:

(a) +/– 20 g in the direction of travel

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

Vehicles of categories M2 and N2:

(a) +/– 10 g in the direction of travel

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

Vehicles of categories M3 and N3:

(a) +/– 6,6 g in the direction of travel

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

2.3. The provisions of section 2.2 shall not apply if the vehicle is approved according to Directives 96/27/EC and 96/79/EC.

2.4. Pressure relief device(s) in accordance with section 5 shall form the fire protection system for a container or container assembly to prevent rupture. Thermal insulation or other protective measures shall not influence the response and performance of the pressure relief device(s).

2.5. A container or container assembly with non-metallic liner(s) shall not be installed in the passenger compartment, luggage compartment or other places where ventilation is not sufficient unless integrated into a system which ensures that permeated hydrogen will be vented outside the vehicle, e.g. it is installed inside a gas tight housing in accordance with section 10.

3. REMOVABLE STORAGE SYSTEM

3.1. The components of a hydrogen system within a removable storage system shall fulfil all the requirements of this Regulation as if the hydrogen system were permanently installed in the vehicle.

3.2. A removable storage system may be removed from the vehicle for refilling. The container(s) or container assembly and the hydrogen components forming the removable storage system shall be permanently installed within the removable storage system.

3.3. A removable storage system shall protect the container(s) or container assembly and hydrogen components forming the removable storage system from damage during the handling operations necessary for installation, removal, storage and handling.

3.4. Effective measures shall be taken to prevent unauthorised removal of the removable storage system.

3.5. A single interface for the flow of hydrogen shall be provided between the removable storage system and the part of the hydrogen system permanently installed in the vehicle. The nominal working pressure of the hydrogen system at the interface shall be less than or equal to 3,0 MPa.

3.6. When the removable storage system is installed in the vehicle the connection with the part of the hydrogen system permanently installed in the vehicle shall be made without the use of tools and shall be capable of fulfilling the requirements of sections 1.2. and 2.2.

3.7. At the time of disconnection of the removable storage system, the volume of hydrogen released shall not exceed 200 Ncm3 and shall not be released near a possible ignition source. The build up of hydrogen due to successive disconnections shall be prevented.

3.8. The part of the removable storage system connector permanently fitted to the vehicle shall be of a unique design for the applicable vehicle type and shall not be compatible with standard refilling nozzles for either hydrogen or other gaseous fuels.

3.9. The flow of hydrogen from a removable storage system shall be prevented if a removable storage system is installed with a higher maximum allowable working pressure than that of the permanent part of the vehicle’s hydrogen system.

3.10. Opening of the automatic valve(s) mounted on a container(s) or a container assembly shall not be possible when the removable storage system is not correctly connected to the permanently fixed section of the vehicle’s hydrogen system. A vehicle interface system shall verify that a correct connection between the removable container system and the vehicle is established before permitting the automatic valve(s) to open. The vehicle interface system shall also verify that the removable storage system is compatible with the vehicle’s hydrogen system before permitting the automatic valve(s) to open.

3.11. Disconnection or removal of the removable storage system shall not be possible unless the automatic valve mounted on a container(s) or a container assembly is in the closed position and no combustion sources are in operation, for example, heaters on the vehicle.

3.12. Use of the hydrogen system shall be prevented if a partial or total failure of the removable storage system connector or electrical connectors between the removable storage system and the vehicle occurs, that may affect the safety of the hydrogen system.

3.13. The installation and removal operations for the removable storage system shall be illustrated on a label attached to the vehicle close to the mounting point of the removable storage system. The label shall also state the nominal working pressure of the container(s) or container assembly and the removable storage system connector.

3.14. A label shall be attached to the removable storage system stating the nominal working pressure of the container(s) or container assembly and the removable storage system connector.

3.15. The EC vehicle type-approval number shall be reproduced on the removable storage system.

4. AUTOMATIC VALVE(S) OR NON-RETURN VALVE(S) FOR ISOLATING A CONTAINER OR CONTAINER ASSEMBLY OR PROPULSION SYSTEM

4.1. Automatic shut-off valves shall be used in compliance with section 6. of Annex VI to Regulation (EC) No 79/2009 and shall be idle closed. If a container assembly is used, the valve shall be mounted directly on or within one container.

4.2. Refuelling connections or receptacles shall be used in compliance wit section 4. of Annex VI to Regulation (EC) No 79/2009. If a container assembly is used, the valve shall be mounted directly on or within one container.

4.3. If a single line is used into the container or container assembly for both refilling and fuel supply, it shall be secured as described in section 4.2. on the refilling line at the junction between the refilling line and the fuel supply line.

4.4. In the event of breakage of the refilling lines or fuel supply line(s), the isolating valves referred to in sections 4.1. and 4.2. shall not be separated from the container or container assembly.

4.5. Automatic valve(s) isolating each container or container assembly, shall close in the event of either a malfunction of the hydrogen system that results in the release of hydrogen or severe leakage between the container or container assembly and the hydrogen conversion system(s).

4.6. The flow of fuel to the propulsion system shall be secured by an automatic valve. This automatic valve shall be operated such that the hydrogen supply to the propulsion system is cut off when the propulsion system is switched off, irrespective of the position of the activation switch, and shall remain so until the propulsion system is required to operate.

4.7. The flow of fuel to other hydrogen conversion system(s) shall be secured by an automatic valve. This automatic valve shall be operated such that the hydrogen supply to other hydrogen conversion system(s) is cut off when the respective hydrogen conversion system is switched off, irrespective of the position of the activation switch, and shall remain so until the hydrogen conversion system is required to operate.

5. PRESSURE RELIEF DEVICE(S)

5.1. For the purposes of containers designed to use compressed (gaseous) hydrogen, a pressure relief device shall be a non-reclosing thermally activated device that prevents a container from bursting due to fire effects.

5.2. A pressure relief device shall be directly installed into the opening of a container or at least one container in a container assembly, or into an opening in a valve assembled into the container, in such a manner that it shall discharge the hydrogen into an atmospheric outlet that vents to the outside of the vehicle.

5.3. It shall not be possible to isolate the pressure relief device from the container protected by the pressure relief device, due to the normal operation or failure of another component.

5.4. The hydrogen gas discharge from pressure relief device shall not be directed:

(a) towards exposed electrical terminals, exposed electrical switches or other ignition sources;

(b) into or towards the vehicle passenger or luggage compartments;

(c) into or towards any vehicle wheel housing;

(d) towards any class 0 component;

(e) forward from the vehicle, or horizontally from the back or sides of the vehicle.

5.5. The internal dimensions of the vent shall not impede the function of the pressure relief device.

5.6. The vent of the pressure relief device shall be protected against blockage, e.g. by dirt, ice, and ingress of water, so far as is reasonably practicable.

5.7. The outlet of the pressure relief device shall be orientated such that if the vent becomes detached from the pressure relief device, the resulting gas flow does not impinge directly on other containers or container assemblies unless they are protected.

6. PRESSURE RELIEF VALVE(S)

6.1. If a pressure relief valve is used, it shall be installed in such a manner that it shall discharge the hydrogen into an atmospheric outlet that vents to the outside of the vehicle.

6.2. It shall not be possible to isolate the pressure relief valve from the hydrogen components or section of the hydrogen system that it protects, by the normal operation or failure of another component.

6.3. The hydrogen gas discharge from pressure relief valves shall not be directed:

(a) towards exposed electrical terminals, exposed electrical switches or other ignition sources;

(b) into or towards the vehicle passenger or luggage compartments;

(c) into or towards any vehicle wheel housing;

(d) towards any class 0 component.

6.4. The vent of the pressure relief valve shall be protected against blockage, e.g. by dirt, ice, ingress of water, etc., so far as is reasonably practicable.

7. RIGID AND FLEXIBLE FUEL LINES

7.1. Rigid fuel lines shall be secured such that they shall not be subjected to critical vibration or other stresses.

7.2. Flexible fuel lines shall be secured such that they shall not be subjected to torsional stresses and abrasion is avoided.

7.3. Rigid fuel lines and flexible fuel lines shall be designed to reasonably minimise stresses in the lines during removal or installation of adjoining hydrogen components.

7.4. At fixing points, rigid fuel lines and flexible fuel lines shall be fitted in such a way that galvanic and crevice corrosion are prevented.

7.5. Rigid fuel lines and flexible fuel lines shall be routed to reasonably minimise exposure to accidental damage whether inside the vehicle, e.g. due to placing or movement of luggage or other loads, or outside the vehicle, e.g. due to rough ground or vehicle jacks etc.

7.6. At passages through the vehicle body or other hydrogen components, the fuel lines shall be fitted with grommets or other protective material.

7.7. If fittings are installed in the passenger or enclosed luggage compartment, the fuel lines and fittings shall be enclosed in a sleeve which meets the same requirements as specified for a gas tight housing in section 10.

8. FITTINGS BETWEEN HYDROGEN COMPONENTS

8.1. The vehicle manufacturer shall ensure that the materials used in fittings are chosen in such a way that galvanic and crevice corrosion are prevented.

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

8.3. Means shall be specified by the manufacturer for leak testing of joints for the purposes of inspection. If leak testing with a surface active agent is specified, any joints shall be made in locations where access is possible.

9. REFILLING SYSTEM

9.1. The receptacle shall be secured against maladjustment and rotation. The receptacle shall also be protected from unauthorised interference, and the ingress of dirt and water so far as is reasonably practicable, e.g. by a locked hatch. The receptacle shall be safe against reasonably foreseeable handling errors.

9.2. The receptacle shall be installed such that access for refilling shall not be required in the passenger, luggage, or in any other unventilated compartment.

9.3. The receptacle shall not be mounted within the external energy absorbing elements, e.g. bumper.

9.4. The nominal working pressure of the receptacle shall be equal to the nominal working pressure of the Class 0 hydrogen components upstream of and including the first pressure regulator.

9.5. It shall be ensured that the propulsion system or hydrogen conversion system(s) excluding safety devices are not operating and that the vehicle is immobilised while refilling.

9.6. Label(s) shall be provided close to the receptacle, for example inside a refilling hatch, showing the following information:

H2 gas

‘xx’ MPa

Where ‘xx’ = nominal working pressure of the container(s).

10. GAS TIGHT HOUSING

10.1. The gas tight housing shall be vented to the atmosphere.

10.2. The ventilation opening of the gas tight housing shall be at the highest point of the housing when installed in the vehicle, as far as reasonably practicable. It shall not ventilate into a wheel arch, nor shall it be aimed at a heat source such as the exhaust. Additionally it shall vent such that hydrogen cannot enter the inside of the vehicle.

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

10.4. During testing the vent line shall be hermetically sealed and the gas tight housing shall meet the leakage requirements of section 1.2. at a pressure of 0,01 MPa and without any permanent deformations.

10.5. Any connecting system shall be secured by clamps, or other means, to the gas tight housing or sleeve and the lead-through to ensure that a joint is formed meeting the leakage requirements of section 10.4.

11. ELECTRICAL INSTALLATION

11.1. The electrical components of the hydrogen system shall be protected against overloads.

11.2. Power supply connections shall be tight against the ingress of hydrogen where hydrogen components are present or hydrogen leaks are possible.

12. SAFETY INSTRUMENTED SYSTEMS

12.1. Safety instrumented systems shall be fail-safe or redundant.

12.2. If safety instrumented systems are fail-safe or self-monitoring electronic systems, the special requirements according to Annex VI shall be applied.

13. REQUIREMENTS FOR THE INSPECTION OF THE HYDROGEN SYSTEM

13.1. Each hydrogen system shall be inspected at least every 48 months after the date of its entry into service, and at the time of any re-installation.

13.2. The inspection shall be performed by a technical service, in accordance with the manufacturers specifications set out in Part 3 to Annex I.

PART 2

Requirements for hydrogen containers designed to use compressed (gaseous) hydrogen

1. INTRODUCTION

This Part sets out the requirements and test procedures for hydrogen containers designed to use compressed (gaseous) hydrogen.

1.1. Container types

Containers shall be classified into types according to the type of construction as referred to in point 1 of Annex IV to Regulation (EC) No 79/2009.

2. GENERAL REQUIREMENTS

2.1. The manufacturer is free to design the shape of a container provided that it fulfils all the appropriate provisions laid down in section 3.

2.2. Container assembly

2.2.1. A container assembly shall be type-approved as one container if both the container assembly and constituent containers are approved in accordance with the provisions laid down in sections 3 and 4.

2.2.2. Alternatively a container assembly shall be type-approved as one container if the container assembly fulfils the provisions laid down in sections 3 and 4. The constituent containers need not fulfil all the provisions laid down in sections 3 and 4 provided that the container assembly fulfils all the provisions of sections 3 and 4 appropriate to the type of materials and method of construction used.

2.2.3. Notwithstanding the requirements of sections 2.2.1. and 2.2.2., a container assembly shall fulfil the requirements of sections 4.2.4. (bonfire test), 4.2.10. (impact damage test) and 4.2.11. (leak test).

2.2.4. A maximum of four containers per container assembly shall be permitted.

2.2.5. Flexible fuel lines shall not be used as integral interconnecting fuel lines in a container assembly.

3. TECHNICAL REQUIREMENTS

3.1. General requirements

Containers shall fulfil the technical requirements specified in sections 3.2. to 3.11.

3.2. Fire protection

The container, pressure relief device(s) and any added insulation or protective material shall collectively protect the container from rupture when exposed to fire. The arrangement of the fire protection system shall be specified.

3.3. Opening threads

Openings with tapered or straight threads may be used in all container types. Threads shall comply with a recognised international or national standard.

3.4. Exterior environmental protection

Any coatings applied to containers shall be such that the application process does not adversely affect the mechanical properties of the container. The coating shall facilitate subsequent in-service inspection and the manufacturer shall provide guidance on coating treatment during such inspection to ensure the continued integrity of the container.

3.5. Material requirements

3.5.1. General

Materials used shall be suitable for the service conditions specified in section 2.7. Incompatible materials shall not be in contact with each other.

3.5.2. Steel

3.5.2.1. Steels for containers and liners shall conform to the material requirements of sections 6.1 to 6.4 of ISO 9809-1 or sections 6.1. to 6.3. of ISO 9809-2 as appropriate.

3.5.2.2. Stainless steels for containers and liners shall conform to sections 4.1. to 4.4. of EN 1964-3.

3.5.2.3. Welded stainless steels for liners of type 3 containers shall conform to sections 4.1. to 4.3. of EN 13322-2 as appropriate.

3.5.3. Aluminium alloy

3.5.3.1. Aluminium alloys for containers and liners shall conform to the material requirements of sections 6.1. and 6.2. of ISO 7866.

3.5.3.2. Welded aluminium alloys for liners of Type 3 containers shall conform to sections 4.2. and 4.3. of EN 12862.

3.5.4. Plastic liner materials

The material for plastic liners may be thermosetting or thermoplastic.

3.5.5. Fibres

The manufacturer of the container shall keep on file for the intended life of the container design the published specifications for composite materials including principal test results, i.e. tensile test, the material manufacturer’s recommendations for storage, conditions and shelf life.

The manufacturer of the container shall keep on file, for the intended life of each batch of containers, the fibre manufacturer’s certification that each shipment conforms to the manufacturer’s specifications for the product.

3.5.6. Resins

The polymeric material for impregnation of the fibres may be thermosetting or thermoplastic resin.

3.6. Burst pressure ratios

The minimum burst pressure ratios, i.e. the minimum actual burst pressure of the container divided by its nominal working pressure, shall not be less than the values given in Table IV.3.6.

Table IV.3.6.

Minimum Burst Pressure Ratios

Container type Construction Type 1 Type 2 Type 3 Type 4 All metal 2,25 Over-wrap Glass 2,4 3,4 3,5 Aramid 2,25 2,9 3,0 Carbon 2,25 2,25 2,25 Hybrid (1)

3.7. Container manufacturing requirements

3.7.1. Type 1 containers

A forming process shall not be used to close the ends of aluminium alloy containers. The base ends of steel containers that have been closed by forming shall be inspected using NDE or equivalent techniques. Metal shall not be added in the process of closure at the end. Each container shall be examined before end forming operations for thickness and surface finish.

After end forming, containers shall be heat treated to the hardness range specified for the design. Localised heat treatment is not permitted.

If a neck ring, foot ring or attachments for support are provided, they shall be of material compatible with that of the container and shall be securely attached by a method other than welding, brazing or soldering.

3.7.2. Type 2, 3 and 4 containers

3.7.2.1. Composite filament winding

When composite containers are fabricated from a liner over-wrapped with continuous filament windings, the filament winding operations shall be computer or mechanically controlled. During winding the principal parameters shall be monitored and kept within specified tolerances, and documented in a winding record. The principal parameters are:

(a) Fibre type including tex value and sizing;

(b) Number of fibre tows per bandwidth;

(c) Type of resin and resin components mix ratio;

(d) Manner of impregnation, weight or volume fraction of resin or fibre;

(e) Winding program reference and winding angle;

(f) Number of winding rotations hoop;

(g) Number of windings cycles helical (type 3 and 4 containers only);

(h) Band width;

(i) Winding tension;

(j) Winding speed,

(k) Temperature of the resin.

3.7.2.2. Curing of thermosetting resins

After completion of filament winding, thermosetting resins shall be cured by heating using a predetermined and controlled time-temperature profile. The time-temperature history shall be documented during the curing.

The maximum curing time and temperature for containers with aluminium alloy liners shall be below the time and temperature that adversely affect the properties of the metal.

For type 4 containers the curing temperature for thermosetting resins shall be at least 10 °C below the softening temperature of the plastic liner.

3.7.2.3. Auto-frettage

Auto-frettage, if used, shall be carried out before the hydraulic test. The auto-frettage pressure shall be within the limits established by the manufacturer.

3.7.2.4. Metallic liners

Welding of stainless steel liners shall conform to sections 6.1., 6.2. and 6.4. of EN 13322-2. Welding of aluminium alloy liners shall conform to sections 4.1.2. and 6.1. of EN 12862.

3.8. Container markings

On each container, and where applicable the outer surface of a group of permanently encapsulated containers, the manufacturer shall provide clear permanent markings with a font not less than 6 mm high. Marking shall be made either by labels incorporated into resin coatings, adhesive labels, low stress stamps used on the thickened ends of type 1 and 2 containers, or any combination of the above means of marking. Adhesive labels and their application shall be in accordance with ISO 7225, or an equivalent standard. Multiple labels are allowed and should be located such that mounting brackets do not obscure them. In addition to the EC component type-approval mark set out in Part 3 of Annex II, every container type-approved in accordance with this Regulation shall bear a marking place with the following data clearly legible:

(a) Name of the manufacturer;

(b) A unique serial number for every container;

(c) a label as set out in section 3.2 of Annex V;

(d) Nominal working pressure (MPa) at 15 °C;

(e) Year and month of manufacture, e.g. 2009/01;

(f) ‘DO NOT USE AFTER yyyy/mm’ where yyyy/mm is the year and month of manufacture plus the approved service life of the container. However, yyyy/mm may be based on the date of dispatch of the container from the manufacturer, provided that it has been stored in a dry location without internal pressure;

(g) ‘Number of filling cycles xxxxx’ where xxxxx is the number of filling cycles in accordance with section 2.7.6.

3.9. Batch test requirements

3.9.1. Batch test

3.9.1.1. General

The manufacturer shall conduct batch testing on finished containers that are representative of normal production. The finished containers to be tested shall be randomly selected from each batch. A batch shall not exceed 200 finished containers plus those finished containers to be used in destructive tests, or one shift of successive production, whichever is greater.

The frequency of batch testing can be reduced as follows:

(a) If on 10 sequential batches of containers, none of the vessels leak or rupture within 1,5 times the required number of cycles, then the pressure cycle testing may be reduced to once per 5 batches. If any tested vessel fails to meet the requirement of 1,5 times the number of pressure cycles, then batch testing shall be required for the next five batches to re-establish the reduced frequency of testing.

(b) If on 10 sequential batches of containers, none of the vessels leak or rupture within 2 times the required number of cycles, then the pressure cycle testing may be reduced to once per 10 batches. If any tested vessel fails to meet the requirement of 2 times the number of pressure cycles, then batch testing shall be required for the next ten batches to re-establish the reduced frequency of testing.

(c) If more than 3 months elapse since the last batch pressure cycle test, then a vessel from the next batch of production shall be pressure tested to maintain the reduced frequency.

The following batch tests are required:

(a) One finished container shall be subjected to the ambient temperature pressure cycle test at the frequency given in section 3.9.1.2.;

(b) One finished container, liner or heat-treated test sample that is representative of finished containers or liners, shall be subjected to the other tests specified in Table IV.3.9.;

(c) One finished container shall be subjected to the burst test. If a finished container passes the ambient temperature pressure cycle test the same container may be subjected to the burst test;

(d) If an exterior environmental protective coating is used, e.g. organic coating/paint, one finished container or test sample that is representative of the batch shall be subjected to the coating batch test.

If more containers than required are subjected to the tests, all results shall be documented.

All containers represented by a batch test that fail to meet the specified requirements shall follow the procedures specified in section 3.9.2.

Table IV.3.9.

Batch tests

3.9.1.2. Frequency of ambient temperature pressure cycling test

Finished containers shall be subjected to the ambient temperature pressure cycling test at a test frequency defined as follows:

(a) One container from each batch shall be pressure cycled for 3,0 times the number of filling cycles in accordance with section 2.7.6.;

(b) If on 10 sequential production batches of containers, none of the pressure cycled containers in point a) leaks or ruptures within 4,5 times the number of filling cycles in accordance with section 2.7.6., then the pressure cycle test can be reduced to one container from every 5 batches of production with the container selected from the first of the 5 batches;

(c) If on 10 sequential production batches of containers, none of the pressure cycled containers in point a) leaks or ruptures within 6,0 times the number of filling cycles in accordance with section 2.7.6., then the pressure cycle test can be reduced to one container from every 10 batches of production with the container selected from the first of the 10 batches;

(d) Should more than 3 months have expired since the last batch of production, then a container from the next batch of production shall be pressure cycle tested in order to maintain the reduced frequency of batch testing in points (b) or (c);

(e) Should any reduced frequency pressure cycle test container points (b) or (c) fail to meet 3,0 times the number of filling cycles in accordance with section 2.7.6., then the batch pressure cycle test frequency in point a) shall be reintroduced for at least 10 production batches in order to re-establish the reduced frequency of batch pressure cycle testing in points (b) or (c);

(f) Should any container referred to in points a), b) or c) fail within 3,0 times the number of filling cycles in accordance with section 2.7.6., then the cause of failure shall be determined and corrected following the procedures in section 3.9.2. The pressure cycle test shall then be repeated on three additional containers from that batch. Should any of the three additional containers fail to meet 3,0 times the number of filling cycles in accordance with section 2.7.6., the batch shall be rejected. The manufacturer shall demonstrate that containers produced since the last successful batch test meet all batch test requirements.

3.9.2. Failure to meet test requirements

In the event of failure to meet the test requirements, retesting or reheat treatment and retesting shall be carried out as follows:

(a) If there is evidence of a fault in carrying out a test, or an error of measurement, a further test shall be performed. If the result of this test is satisfactory, the first test shall be ignored;

(b) If the test has been carried out in a satisfactory manner, the cause of the test failure shall be identified.

If the failure is considered to be due to the heat treatment applied, the manufacturer may subject all the containers of that batch to a further heat treatment.

If the failure is not due to the heat treatment applied, all the identified defective containers shall be rejected or repaired by an approved method. The non-rejected containers shall then be considered as a new batch.

In both cases all the relevant prototype or batch tests needed to prove the acceptability of the new batch shall be repeated. If one or more tests prove even partially unsatisfactory, all containers of the batch shall be rejected.

3.10. Production examination and test requirements

Production examination and tests shall be carried out on all containers during manufacture and after completion, as follows:

(a) Verification that the principal dimensions and mass of the finished container and of any liner and over-wrap are within design tolerances;

(b) Verification of compliance with principal manufacturing parameters, referred to in the appendix to the information document as set out in Part 1 to Annex II, including examination of any specified surface finish with special attention to deep drawn surfaces and folds or laps in the neck or shoulder of forged or spun end enclosures or openings;

(c) For metallic containers and liners, NDE in accordance with Annex B of ISO 9809 or Annex C of EN 1964-3 or Annex B of EN 13322-2 as appropriate, or a demonstrated equivalent method capable of detecting the maximum defect size allowed, to verify that the maximum defect size does not exceed the size specified in the design as determined below.

In addition welded stainless steel liners shall also be examined in accordance with section 6.8.2. of EN 13322-2, and welded aluminium alloy liners shall be examined in accordance with sections 6.2.1. (second section), and 6.2.3. of EN 12862.

The design of type 1, 2 and 3 containers shall identify the maximum allowable defect size at any location in the metal container or liner that will not grow to a critical size within either the specified retest period or service life if no retest is specified. The critical defect size is defined as the limiting through-wall (container or liner) thickness defect that would allow stored gas to be discharged without rupturing the container. Defect sizes for the rejection criteria for ultrasonic scanning or equivalent, shall be smaller than the maximum allowable defect sizes. For type 2 and 3 containers, it shall be assumed that there is no damage to non-metallic materials due to any time-dependent mechanisms. The allowable defect size for NDE shall be determined by an appropriate method.

Containers shall meet the following requirements:

(a) Hardness test for metallic containers and liners in accordance with section 4.1.8.;

(b) Hydraulic test, in accordance with section 4.2.15.;

(c) Leak test for type 4 containers and type 3 with welded metal liners, in accordance with section 4.2.11.;

(d) Verification of markings, in accordance with section 3.8.

A summary of the required production examination and tests for each container is provided in Table IV.3.10.

Table IV.3.10.

Production examination and tests

3.11. Modifications

Modifications may be approved in accordance with the reduced test programme specified in Table IV.3.11. Any major changes that are not covered by Table IV.3.11. shall be subjected to full approval testing.

Table IV.3.11.

Approval testing of modifications

Type of test Materials sections 4.1.1.-4.1.8., as applicable Hydrogen compatibility section 4.1.7. Burst section 4.2.1. Ambient temp. pressure cycling section 4.2.2. Lbb Performance section 4.2.3. Bonfire section 4.2.4. Penetration section 4.2.5. Chemical exposure section 4.2.6. Composite flaw tol