ISO 9809-1:2019 download free.Gas cylinders Design, construction and testing of refillable seamless steel gas cylinders and tubes Part 1: Quenched and tempered steel cylinders and tubes with tensile strength less than 1 100 MPa.
1 Scope
ISO 9809-1 specifies minimum requirements for the material, design. construction and workmanship, manufacturing processes, examination and testing at time of manufacture for refillable seamless steel gas cylinders and tubes with water capacities up to and including 450 I.
It Is applicable to cylinders and tubes for compressed, liquefied and dissolved gases and for quenched and tempered steel cylinders and tubes with a maximum actual tensile strength R11 of less than 1 100 MPa.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content constitutes requirements of ISO 9809-1. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.
ISO 148-1. Metallic materials — Charpy pendulum Impact test — Part 1: rest method
ISO 6506-1, Metallic materials — Brinell hardness test — Part 1.- Test method
ISO 6508-1, Metallic materials — Rockwell hardness test — Port 1: Test method
ISO 6892-1, Metallic materials — Tensile testing — Part I: Method of test at room temperature
ISO 9712, Non-destructive testing — Qualification and cert Ificatlon ofNDrpersor,nel
ISO 10286. Gas cylinders — Terminology
ISO 11114-1, Gas cylinders — Compatibility of cylinder and valve materials with gas contents — Parr 1:
Metallic materials
ISO 11114-4, fransportable gas cylinders — CompatibIlity of cylinder and valve materials with gas contents — Part 4: Test methods for selecting steels resistant to hydrogen embrlttkment
ISO 13341. Gas cylinders — Fitting of valves togas cylinders
ISO 13769. Gas cylinders — Stamp marking
u ratio of distance between knife edges or platens in the flattening test to average cylinder wall thickness at the position of test
V water capacity of cylinder, In litres
w width, in millimetres, of the tensile test piece (see Figure6)
5 Inspection and testing
Assessment of conformity to ISO 9809-1 standard shall take Into account the applicable regulations of the countries of use.
To ensure that cylinders conform to this document, they shall be subject to Inspection and testing In accordance with Claasrs9. j. and 11.
Tests and examinations performed to demonstrate compliance with this document shall be conducted using instruments calibrated before being put into service and thereafter according to an established programme.
6 MaterIals
6.1 General requirements
6.1.1 Materials for the manufacture olgas cylinders shall fall within one of the following categories:
a) internationally recognized cylinder steels;
b) nationally recognized cylinder steels;
c) new cylinder steels resulting from technical progress.
For all categories, the relevant conditions specified in 6.2 and 62 shall be satisfied.
6.1.2 The material used for the manufacture of gas cylinders shall be steel, other than rimming quality with non.ageing properties and shall be fully killed with aluminium and/or silicon.
In cases where examination of this non.ageing property is required by the customer, the criteria by which It is to be specified should be agreed with the customer and inserted in the order.
6.1.3 The cylinder manufacturer shall establish means to identify the cylinders with the cast of steel from which they are made.
6.1.4 Grades of steel used for cylinder manufacture shall be compatible with the Intended gas service. e.g. corrosive gases and embrittling gases (see ISO 11114.1).
6.1,5 Wherever continuously cast billet material Is used, the manufacturer shall ensure that there are no deleterious Imperfections (porosity) In the matertal to be used for making cylinders (see 22.2).
6.2 Controls on chemical composition
62.1 The chemical composition of all steels shall be defined at least by:
— the carbon, manganese and silicon contents in all cases
— the chromium, nickel and molybdenum contents or other alloying elements intentionally added to the steel:
6.3 TypIcal steels
Two typical internationally recognized steel types which have provided safe performance over many years are:
a) chromium molybdenum steel (quenched and tempered);
b) carbon manganese steel (quenched and tempered).
The chemical compositions of these steels, subject to the controls spccthed in (I2J.. are given in AnnexE
6.4 Heat treatment
6.4.1 The cylinder manufacturer shall certify the heat treatment process applied to the finished cylinders.
6.4.2 Quenching In media other than mineral oil Is permissible provided that:
— the method produces cylinders free of cracks.
— the manufacturer ensures that the rate of cooling does not produce any cracks In the cylinder.
— every production cylinder is subjected to a method of non-destructive testing to prove freedom from cracks, if the average rate of cooling in the medium is greater than HO % of that in water at 20 C without additives.
— during the production of cylinders, the concentration of the quend,ant is checked and recorded during every shift to ensure that the limits are maintained. Further documented checks shall be carried out to ensure that the chemical properties of the quenchant are not degraded.
6.4.3 The tempering process shall achieve the required mechanical properties.
The actual temperature to which a type of steel is subjected for a given tensile strength shall not deviate by more than +f—30 °C from the temperature specified by the cylinder manufacturer.
6.5 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 to the satisfaction of the inspector.
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 oltest failure shall be Identified.
1) If the failure Is considered to be due to the heat treatment applied, the manufacturer may subject all the cylinders Implicated by the failure to only one further heat treatment. e.g. If the failure Is In a test representing the prototype or batch cylinders. Test failure shall require reheat treatment of all the represented cylinders prior to retesting.
This reheat treatment shall consist of either re-tempering or complete reheat treatment.
Whenever cylinders are reheat treated, the minimum guaranteed wall thickness shall be maintained.
Only the relevant prototype or batch tests needed to prove the acceptability of the new batch shall be performed again. if one or more tests prove even partially unsatisfactory, all cylinders of the batch shall be rejected.
NOTE It is generally assumed that Ph = 1.5 times working pressure for compressed gases for cylinders designed and manufactured to conform with this document.
NOTE 2 For some applications, such as tubes assembled in batteries to equip trailers or skids (ISO modules) or MEGCu for the transportation and distribution of gases, it is important that stresses associated with mounting the tube (e.g. bending stresses, see Aanex.E. torsional stresses, dynamic loadings) are considered by the assembly manufacturer and the tube manufacturer.
NOTE 3 In addition, during hydraulic pressure testing, tubes could be supported or lifted by their necks therefore, potential bending stresses are considered. For general guidance, see Annes £.
7.4 Design of convex ends (heads and bases)
7.4.1 When convex base ends (see £lgureJ.) are uscd the thickness. I,. at the centre of a convex end shall be not less than that requwed by the following criteria: where the insdc knuckle radius. r, is not less than 0,07 SD then:
b a 1.5 a for 0,40> H/fl a 0,20;
baaforH/DO,40.
To obtain a satisfactory stress distribution in the region where the end oins the shell, any thickening of the end when required shall be gradual from the point of juncture, particularly at the base. For the application of this rule, the point of juncture between the shell and the end is defined by the horizontal lines indicating dimension H in Ftgurei
Shape b) in Figurel shall not be exduded from this requirement.
7.4.2 The cylinder manufacturer shall prove by the pressure cycling test detailed in 22 that the design is satisfactory.
The shapes shown In Figure 1 are typical of convex heads and base ends. Shapes a). b), d] and e) are base ends and shapes C) and f) are heads.
tensile strength range guaranteed by the manufacturer. The values may be plotted on a diagram to identify their position.
NOTE I Methods for measuring the surface indentations other than given in ISO 6506•l or ISO 6508•1 can be used subect to agreement between the parties concerned, provided that an equal level of accuracy can be demonstrated
NOTE 2 The hardness value at any single location can be the average of a maximum of three test results.
11.4 Leak test
Only for cylinders with the base ends formed from tube, the manufacturer shall employ such manufacturing techniques and apply such tests as will demonstrate to the satisfaction of the Inspector that the cylinders do not leak.
The following are examples of typical testing procedures:
— a pneumatic leakage test where the base end shall be clean and free from all moisture on the test pressure side. The inside area of the cylinder base surrounding the closure shall be subfrcted to a pressure equal to at least two thirds of the test pressure of the cylinder for a minimum of I mm; this area shall be not less thati 20 mm In diameter around the closure and at least 6 % of the total base area. The opposite side shall be covered with water or another suitable medium and closely examined for Indication of leakage.
— alternative tests on finished cylinders (e.g. helium leak or pneumatic leak tests). For both the above leak testing procedures, cylinders that leak shall be rejected.
11.5 Capacity check
The manufacturer shall verify that the water capacity conforms to the design drawing.
12 Certification
Each batch of cylinders shall be covered by a certificate signed by the Inspector to the effect that the cylinders meet the requirements of this document in alt respects. Annex D provides a typical example of a suitably worded acceptance certificate. Other formats with at least the same content are also acceptable.
Copies of the certificate shall be Issued to the manufacturer. The original certificate shall be retained by the inspector and the copies shall be retained by the manufacturer.
NOTE Regarding certificates, national regulations can contain additional or overriding requirements.
13 MarkIng
Each cylinder shall be permanently marked on the shoulder or on a reinforced part of the cylinder or on
a permanently fIxed collar or neck ring. in accordance with ISO 13769.
NOTE Regarding marking, national regulations can contain additional or overriding requirements.