1、PUBLISHED DOCUMENTPD CEN/TR 15444:2006Transportable gas cylinders Gas cylinders conforming to the TPED to be used for PED applications Applicability and justificationsICS 23.020.30g49g50g3g38g50g51g60g44g49g42g3g58g44g55g43g50g56g55g3g37g54g44g3g51g40g53g48g44g54g54g44g50g49g3g40g59g38g40g51g55g3g36
2、g54g3g51g40g53g48g44g55g55g40g39g3g37g60g3g38g50g51g60g53g44g42g43g55g3g47g36g58PD CEN/TR 15444:2006This Published Document was published under the authority of the Standards Policy and Strategy Committee on 30 April 2007 BSI 2007ISBN 978 0 580 50567 6National forewordThis Published Document was pub
3、lished by BSI. It is the UK implementation of CEN/TR 15444:2006.The UK participation in its preparation was entrusted by Technical Committee PVE/3, Gas containers, to Subcommittee PVE/3/3, Transportable gas containers Cylinder design, construction and testing at the time of manufacture.A list of org
4、anizations represented on PVE/3/3 can be obtained on request to its secretary.This publication does not purport to include all the necessary provisions of a contract. Users are responsible for its correct application.Amendments issued since publicationAmd. No. Date CommentsTECHNICAL REPORTRAPPORT TE
5、CHNIQUETECHNISCHER BERICHTCEN/TR 15444September 2006ICS 23.020.30English VersionTransportable gas cylinders - Gas cylinders conforming to theTPED to be used for PED applications - Applicability andjustificationsBouteilles gaz transportables - Bouteilles gazconformes la Directive sur les quipements s
6、ouspression transportables, utiliser pour des applicationsrelevant de la Directive sur les quipements sous pression- Applicabilit et justificationsOrtsbewegliche Gasflaschen - Gasflaschen entsprechendder TPED fr PED Anwendungen - Anwendbarkeit undBegrndungThis Technical Report was approved by CEN on
7、 13 May 2006. It has been drawn up by the Technical Committee CEN/TC 23.CEN members are the national standards bodies of Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France,Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, N
8、orway, Poland, Portugal, Romania,Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.EUROPEAN COMMITTEE FOR STANDARDIZATIONCOMIT EUROPEN DE NORMALISATIONEUROPISCHES KOMITEE FR NORMUNGManagement Centre: rue de Stassart, 36 B-1050 Brussels 2006 CEN All rights of exploitation in any form
9、and by any means reservedworldwide for CEN national Members.Ref. No. CEN/TR 15444:2006: E2 Contents Page Foreword3 Introduction .4 1 Scope 5 2 Normative references 5 3 Terms and definitions .5 4 Technical justification .6 Bibliography 9 CEN/TR 15444:20063 Foreword This document (CEN/TR 15444:2006) h
10、as been prepared by Technical Committee CEN/TC 23 “Transportable gas cylinders”, the secretariat of which is held by BSI. CEN/TR 15444:20064 Introduction This CEN technical report has been prepared to address the essential requirements of the Pressure Equipment Directive (PED) 97/23/EC with regard t
11、o European Standards prepared originally for transportable gas cylinders, which address the essential safety requirements of the Transportable Pressure Equipment Directive (TPED) 99/36/EC. CEN/TR 15444:20065 1 Scope This Technical Report provides a rationale and technical justification for certain E
12、uropean Standards for transportable gas cylinders, produced in accordance with the requirements of the Transportable Pressure Equipment Directive (TPED), to be used for applications currently listed in the Pressure Equipment Directive (PED). Its purpose is to prove equivalence of approach in the two
13、 directives and demonstrate equivalence to the overall level of safety in the Essential Safety Requirements (ESRs) of the PED, thereby allowing European Standards and EEC directives listed in this Technical Report to be used to fulfil the requirements of the PED, provided that their filling conditio
14、ns fulfil the requirements of ADR/RID (P200, 4.1.4.1), in respect of portable fire extinguishers and breathing apparatus. 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undate
15、d references, the latest edition of the referenced document (including any amendments) applies. EN 1964-1, Transportable gas cylinders Specification for the design and construction of refillable transportable seamless steel gas cylinders of water capacities from 0,5 litre up to and including 150 lit
16、res Part 1: Cylinders made from seamless steel with an Rmvalue of less than 1 100 MPa EN 1964-2, Transportable gas cylinders Specification for the design and construction of refillable transportable seamless steel gas cylinders of water capacities from 0,5 litre up to and including 150 litres Part 2
17、: Cylinders made from seamless steel with an Rmvalue of 1 100 MPa and above EN 1964-3, Transportable gas cylinders Specification for the design and construction of refillable transportable seamless steel gas cylinders of water capacities from 0,5 litre up to and including 150 litres Part 3: Cylinder
18、s made of seamless stainless steel with an Rmvalue of less than 1 100 MPa EN 1975, Transportable gas cylinders Specification for the design and construction of refillable transportable seamless aluminium and aluminium alloy gas cylinders of capacity from 0,5 litre up to 150 litre EN 12245, Transport
19、able gas cylinders Fully wrapped composite cylinders EN 12257, Transportable gas cylinders Seamless, hoop wrapped composite cylinders EN 13322-1, Transportable gas cylinders Refillable welded steel gas cylinders Design and construction Part 1: Carbon steel prEN ISO 10286:2006, Gas cylinders Terminol
20、ogy (ISO/FDIS 10286: 2006) EN ISO 13769 Gas Cylinders, Stampmarking 3 Terms and definitions For the purposes of this document the terms and definitions in prEN ISO 10286 apply. CEN/TR 15444:20066 4 Technical justification 4.1 General The following standards, together with those referred to in the Bi
21、bliography, have been produced to support the essential requirements of the TPED. EN 1964-1, -2 and -3 for seamless steel cylinders; EN 1975 for seamless aluminium alloy cylinders; EN 12245 for fully wrapped, composite cylinders; EN 12257 for hoop wrapped, composite cylinders; EN 13322-1 for welded
22、steel cylinders. They have been adjudged by the experts to conform to the requirements of the TPED, the Regulations concerning the International Carriage of Dangerous Goods (RID) and the European Agreement on the International Carriage of Dangerous Goods by Road (ADR). Gas cylinders are manufactured
23、 using stock materials which are transformed to their final shape, then carefully heat treated and finally tested to well defined criteria. Hence the manufacture of gas cylinders follows a different approach from that of conventional pressure vessels. In the case of gas cylinders, the mechanical pro
24、perties of the final product are significantly altered during the manufacturing process from those of the stock materials. Consequently the mechanical properties of the stock materials, guaranteed by material standards, are of little relevance. 4.2 Application 4.2.1 General It is proposed by this Te
25、chnical Report that cylinders manufactured in accordance with the design and manufacturing standards quoted in 4.1 are suitable for the design and construction of seamless or welded portable fire extinguishers and breathing apparatus (see clause 1.1 (a) of Article 3, PED). The dimensions of these cy
26、linders should reflect the limits in the various standards. 4.2.2 Materials a) Steels Materials used in the steel cylinder design standards and EEC Directive 84/525 need to meet stringent mechanical properties. Hence their composition is defined according to a narrow specification, as is the manufac
27、turing process e.g. non-ageing, non-rimming quality steel is stipulated. Additionally full materials compatibility with the gas contained is an essential, normative requirement in gas cylinder manufacturing standards (EN ISO 11114-1 refers). b) Aluminium alloys Materials used in the aluminium alloy
28、cylinder design standards and EEC Directive 84/526 are referred back to recognised and registered compositions within the International Aluminium Federation (IAF), for most commonly used materials. These materials and other permitted alloys shall meet stringent mechanical properties. Hence their com
29、position is defined according to a narrow specification. Additionally full materials compatibility with the gas contained is an essential, normative requirement in gas cylinder manufacturing standards (EN ISO 11114-1 refers). CEN/TR 15444:20067 c) Composites Liner materials When steel or aluminium a
30、lloy is used, conditions in 4.2.2 a) and 4.2.2 b) above apply. In the case of non-metallic liners, the latter are non-load sharing but shall be both chemically compatible (EN ISO 11114-2 and EN ISO 11114-3, where applicable, refer) with the gas contained and be leak-tight. . Additionally full materi
31、als compatibility of the liner, with the gas contained is an essential, normative requirement in gas cylinder manufacturing standards (EN ISO 11114-1 refers). Overwrap materials These are closely specified by the manufacturer and subsequently verified, as required in the manufacturing/design standar
32、d, by various stringent tests on the starting materials and completed cylinders. 4.2.3 Safety considerations 4.2.3.1 General The PED requires a proof test at the final assessment which will normally take the form of a hydrostatic pressure test at a pressure (PT) at least equal, where appropriate, to
33、 the maximum allowable pressure (PS) x 1,43. For gas cylinders this factor may be lower and depends on the gas used and the maximum expected allowable temperature, TS. However, in no case shall the maximum allowable pressure PS ever exceed PT. Furthermore in order to compensate for this possible low
34、er ratio, gas cylinders produced and tested according to the standards listed in 4.1 are subjected to stringent experimental tests at various stages of their design and production. One way of illustrating the pressure considerations of the two Directives (PED/TPED) is shown in Figure 1. Here it can
35、be seen that the wall stress at maximum allowable pressure at maximum temperature for gas cylinders designed under TPED, does not exceed the maximum allowable stress as per the PED. Figure 1 shows an example of the pressures relating to cylinders used for breathing apparatus applied in accordance wi
36、th the PED and the TPED for a case where PT = 1,43 x PS. The only pressure they have in common is the maximum allowable pressure (PS) at the maximum allowable temperature for the PED on the left and the maximum developed pressure at elevated temperature for the TPED on the right. The PED requires a
37、proof test at the final assessment which will normally take the form of a hydrostatic pressure test at a pressure (PT) at least equal, where appropriate, to the maximum allowable pressure (PS) multiplied by 1.43 i.e. PT 1,43 x PS. TPED cylinders have a test pressure (PH) based on the working pressur
38、e (PW) at 15 C, i.e. PH 1,5 x PW. Additionally TPED cylinders are required to pass the minimum yield pressure (Py) and minimum burst pressure (Pb) requirements. If all these requirements are plotted together, as in Figure 1, it is evident that the maximum wall stress at test pressure for a TPED cyli
39、nder is 77% of yield stress which would result in a maximum wall stress at test pressure for an equivalently designed PED cylinder of less than 95% of yield stress. This example thus proves that the safety factors for TPED cylinders are comparable with those of PED. CEN/TR 15444:20068 Pressure (bar)
40、 720 bar Burst pressure (Pb= 1,6 x PH) (1) 585 bar Yield pressure (Py= 1/F x PH) (2) (3) Test pressure (PT = 1,43 x PS) 535 bar 450 bar Test pressure (PH = 1,5 x PW) (4) (5) Max. pressure for limiting device (1,1 x PS) 411 bar (6) Max. allowable pressure at max. temperature (PS) 374 bar374 bar Max.
41、developed pressure for air at 60 C (7) 300 bar Working pressure at 15 C (PW) (8) 0 bar Key 1 Minimum burst pressure 2 Minimum yield pressure 3 Test pressure according to the PED (at which pressure the wall stress does not exceed 95% of yield stress) 4 Test pressure according to the TPED (this pressu
42、re is used for wall thickness calculation whereby the maximum wall stress does not exceed 77% of yield stress) 5 Opening pressure of pressure limiting device according to the PED 6 Maximum allowable pressure according to the PED (in the case of the example at 60 C) 7 Maximum developed pressure at el
43、evated temperature (in the case of the example at 60 C) 8 Maximum working pressure at 15C according to the TPED (ADR) Figure 1 Schematic representation of an example of pressures for breathing apparatus cylinders 4.2.3.2 Experimental testing of a new design (at design stage) In addition to the conve
44、ntional tests that PED vessels undergo, gas cylinders are subjected to type approval regimes including two main types of tests. These are Pressure cycling and Burst testing. Cylinders are required to withstand a considerable amount of pressure cycles, e.g. 12 000 cycles at test pressure for monolith
45、ic gas cylinders without any deformation, leakage or burst, for each design. Additionally, for each new design, cylinders are required to undergo burst tests and meet a value at least 60% higher than the test pressure (up to 100% in the case of some types of composite cylinder). CEN/TR 15444:20069 4
46、.2.3.3 Experimental testing of a batch To verify conformity to the design, for most cylinder geometries, cylinders from batches of 200 off or fewer are tested to ensure mechanical property conformity and burst characteristics. The mechanical properties are checked by tensile tests, bend tests and to
47、ughness tests. Burst test results have to meet the requirements in 4.2.3.2. For composites at least one cylinder per 1 000 is also cycle tested to confirm conformity to design. 4.2.3.4 Experimental testing on individual cylinders Tests on every cylinder include a hydrostatic pressure test, visual an
48、d dimensional checks, and neck thread checks, as in the PED, but additionally each seamless cylinder is hardness tested to confirm conformance to heat-treatment and homogeneity requirements. Non-destructive examinations, e.g. ultrasonics, are performed on seamless steel cylinders and steel liners wh
49、ere necessary. 4.2.3.5 Additional experimental testing For more advanced cylinder designs, the standards specify mandatory additional tests: e.g. flawed fatigue and flawed burst tests for high strength steel and aluminium alloy cylinders, sustained load cracking tests for all aluminium alloy cylinders, extreme temperature cycling/creep tests for composites etc. 4.2.4 Design by experimental methods Some categories of cylinders are initially designed using fin
