GB/T 24162-2022 PDF English
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Periodic inspection and evaluation of hoop wrapped fibre reinforced composite gas cylinders with metal liners of compressed natural gas for automotive vehicles
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| GB 24162-2009 | English | 559 |
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[GB/T 24162-2009] Periodic inspection and evaluation of hoop wrapped fibre reinforced composite gas cylinders with metal liners of compressed natural gas for automotive vehicles
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GB/T 24162-2022: Periodic inspection and evaluation of hoop wrapped fibre reinforced composite gas cylinders with metal liners of compressed natural gas for automotive vehicles
---This is an excerpt. Full copy of true-PDF in English version (including equations, symbols, images, flow-chart, tables, and figures etc.), auto-downloaded/delivered in 9 seconds, can be purchased online: https://www.ChineseStandard.net/PDF.aspx/GBT24162-2022
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 23.020.30
CCS J 74
Replacing GB/T 24162-2009
Periodic inspection and evaluation of hoop wrapped fibre
reinforced composite gas cylinders with metal liners of
compressed natural gas for automotive vehicles
ISSUED ON: JULY 11, 2022
IMPLEMENTED ON: FEBRUARY 01, 2023
Issued by: State Administration for Market Regulation;
Standardization Administration of the People's Republic of China.
Table of Contents
Foreword ... 3
1 Scope ... 5
2 Normative references ... 5
3 Terms and definitions... 5
4 Inspection tools, devices, inspection cycles and inspection items ... 7
4.1 Inspection tools and devices ... 7
4.2 Inspection cycles ... 7
4.3 Inspection items ... 8
5 Inspection preparation... 8
5.1 Records ... 8
5.2 In-cylinder medium handling ... 9
5.3 Bottle valve disassembly and surface cleaning ... 9
6 Internal and external appearance inspection and evaluation ... 9
6.1 Damage type ... 9
6.2 Damage level ... 9
6.3 Inspection and evaluation of wrapping layer damage ... 16
6.4 Inspection and evaluation of metal part damage ... 18
7 Inspection and evaluation of cylinder thread ... 20
8 Hydrostatic test ... 20
9 Internal drying ... 21
9.1 Drying method and requirements ... 21
9.2 Drying condition inspection... 21
10 Cylinder valve inspection and assembly ... 21
11 Air tightness test ... 22
12 Work after inspection ... 22
Annex A (informative) Typical cylinder damage and repair illustration ... 23
Annex B (informative) Periodic inspection report for gas cylinders ... 27
Periodic inspection and evaluation of hoop wrapped fibre
reinforced composite gas cylinders with metal liners of
compressed natural gas for automotive vehicles
1 Scope
This document specifies the basic methods and technical requirements for periodic
inspection and evaluation of hoop wrapped fibre reinforced composite gas cylinders
with metal liners of compressed natural gas for automotive vehicles (hereinafter
referred to as "the cylinder").
This document applies to refillable gas cylinders of which the nominal working pressure
is 20MPa, 25MPa and 30MPa, the nominal volume is 30L~450L, the storage medium
is compressed natural gas, the working temperature is -40℃~65℃, and it is fixed on
the automotive vehicle as a fuel tank.
2 Normative references
The following referenced documents are indispensable for the application of this
document. For dated references, only the edition cited applies. For undated references,
the latest edition of the referenced document (including any amendments) applies.
GB/T 8335, Special threads for gas cylinders
GB/T 8336, Special thread gauges for gas cylinders
GB/T 9251, Methods for hydrostatic test of gas cylinders
GB/T 10878, Special taps of taper threads for gas cylinders
GB/T 12137, Methods for leakage test of gas cylinders
GB/T 13005, Terminology of gas cylinders
TSG 23, Regulation on Safety Technology for Gas Cylinder
3 Terms and definitions
For the purposes of this document, the terms and definitions defined in GB/T 13005 as
well as the followings apply.
4 Inspection tools, devices, inspection cycles and inspection
items
4.1 Inspection tools and devices
The inspection agency shall have the following tools and devices (but not limited to
these):
a) Lamp: It can clearly illuminate the inner and outer surfaces of the gas cylinder to
be inspected and the surface of its accessories. It shall use an explosion-proof lamp
not exceeding 24V;
b) Special tools such as torque wrench: For the removal and installation of gas
cylinders, cylinder valves or PRD end plugs;
c) Depth gauge: Used to measure the depth of damage such as scratches, dents and
abrasions;
d) Length measuring tools (including rulers, squares and tapes): Used to determine
the length of damage;
e) Ultrasonic thickness gauge: Used to measure the wall thickness of the metal part
of the gas cylinder;
f) Weighing apparatus: Used to measure the weight and volume of gas cylinders;
g) Hydrostatic test device by external test method: Used for hydrostatic test of gas
cylinders;
h) Air tightness test device: Used for air tightness test of gas cylinders;
i) Natural gas recovery unit: Used for the recovery of natural gas;
j) Cleaning device: Used to clean the dirt, corrosion products and contaminants on
the inner and outer surfaces of gas cylinders;
k) Thread gauges and taps: Used for inspection and repair of bottle threads.
4.2 Inspection cycles
4.2.1 The periodic inspection cycle of gas cylinders shall comply with the relevant
provisions of TSG 23.
4.2.2 In the process of use, if in the following situations, it shall check in advance:
a) Gas cylinder or car fire;
b) Gas cylinders are exposed to ambient temperatures higher than 65°C for a long
time;
c) Gas cylinders are impacted or dropped during installation;
d) The car suffered a collision;
e) Cylinder exposure to chemicals;
f) Abnormal sound occurs during use;
g) Be sure that the cylinder has been damaged in some way;
h) Doubt about the safety of gas cylinders.
4.2.3 Cylinders in stock or out of service for more than one inspection period shall be
inspected before being put into use.
4.3 Inspection items
The periodic inspection items of gas cylinders include: internal appearance inspection,
bottle thread inspection, hydraulic pressure test, cylinder valve inspection and assembly,
and air tightness test.
5 Inspection preparation
5.1 Records
5.1.1 Check and record the manufacturing marks and inspection marks of gas cylinders
one by one. The contents of the record include at least manufacturer license number or
agency code, gas cylinder manufacturing standard, gas cylinder number, year and
month of manufacture, nominal working pressure, hydraulic test pressure, design wall
thickness of inner tank, nominal volume, presence or absence of "TAXI" mark, cylinder
valve, manufacturer and model of PRD end plug (if any, the same below), previous
inspection date (year, month), and name or code of the inspection agency. Country shall
be recorded for imported gas cylinders.
5.1.2 For gas cylinders produced by manufacturers that have not obtained a special
equipment manufacturing license, gas cylinders with unclear manufacturing marks or
incomplete items without evidence, and gas cylinders that are not allowed to be reused
according to the safety technical specifications for special equipment, they shall not be
inspected after they are registered. They shall be judged scrapped.
5.1.3 Cylinders whose service life exceeds the design service life from the date of
manufacture shall not be inspected after they are registered. They shall be judged
scrapped. For the gas cylinders used in taxis, if they have been used for more than 8
years, they will not be inspected after registration. They shall be judged scrapped.
5.2 In-cylinder medium handling
Appropriate methods (such as vacuuming or nitrogen replacement) shall be taken to
discharge and properly handle the medium in the cylinder under the conditions of safety,
hygiene and no environmental pollution.
5.3 Bottle valve disassembly and surface cleaning
5.3.1 After confirming that the pressure inside the cylinder is consistent with
atmospheric pressure, remove the cylinder valve and PRD end plug.
5.3.2 For gas cylinders whose valve cannot be opened or removed, they shall be stored
separately from other gas cylinders to be tested. Label them for proper disposal.
5.3.3 Use an appropriate method that does not damage the bottle metal and the wrapping
layer to clean the dirt, corrosion products, contaminants and other debris on the inner
and outer surfaces of the gas cylinder that hinder the appearance inspection, as well as
the loose coating on the outer surface.
6 Internal and external appearance inspection and evaluation
6.1 Damage type
Visual inspection is the primary way to determine cylinder damage. Types of damage
include: corrosion, scratches, bruises, gouges, abrasions, dents, bulges, exposed fibers,
fiber breaks, loose or separated fibers, material loss, delamination, cracks, discoloration
of the cylinder surface (such as carbon deposits, carbonization, chemical attack), traces
of exposure to thermal environments, impact, deterioration of surface materials.
6.2 Damage level
According to the degree of damage, the damage is divided into level 1 damage, level 2
damage and level 3 damage. Level 1 damage does not require repair and can continue
to be used. Level 2 damage can be repaired or consulted with the manufacturer for
disposal advice or judged as scrapped. Level 3 damage cannot be repaired, and the
cylinder shall be judged as scrapped. The damage found in the wrapping layer of the
gas cylinder shall be inspected and evaluated according to Table 1. The damage found
on the metal part of the cylinder shall be inspected and evaluated in accordance with
Cylinders with gas leakage from the cylinder body shall be judged as level 3 damage.
6.3.5 Chemical corrosion
The damage on the cylinder surface caused by chemical product erosion. This damage
may manifest as corrosion, discoloration, pitting, pitting, spotting, blistering, softening,
stress corrosion cracking and resin peeling. In severe cases, the fibers of the cylinder
will be broken or loose.
When it is confirmed that the known chemical contaminated by the gas cylinder will
not cause damage to the gas cylinder, it shall be judged as a level 1 damage. Spotting,
blistering, softening, resin peeling, fiber breakage, or loosening caused by chemical
product erosion on cylinders shall be judged as level 3 damages. When the chemical
product cannot be determined, or the impact on the cylinder material cannot be
confirmed, it shall also be judged as a level 3 damage.
6.3.6 Ageing
If the cylinder is exposed to sunlight, rain and atmospheric environment for a long time,
the wrapping layer on the outer surface of the cylinder will age. As a result,
discoloration or degradation of the outer surface material may occur. If there is no fiber
breakage or collapse of the wrapping layer, it shall be judged as level 1 or level 2
damage. If the fiber loosens or breaks, it shall be judged as a level 3 damage.
6.3.7 Impact damage
Impact damage is caused by a strong impact on the surface of the cylinder. Impact
damage can cause fiber breakage and delamination of the wrapping layer. Surface
damage associated with impact damage is dents, scratches, grooves, scratches, bruises,
peeling, punctures, broken or loose fibers, cracked resin, discoloration, or deformation
of the cylinder. Cylinder surfaces shall be carefully inspected in the presence of such
damage.
The known impacted areas, areas of surface damage, and the inner wall of the cylinder
shall be inspected, so as to determine if the inner wall has been damaged. Damage to
the inner wall can cause permanent deformation of the cylinder. A dent is a more serious
sign of damage. Cylinders showing signs of such damage shall be carefully inspected.
It shall be judged as a level 2 or level 3 damage. Any bulge in the cylinder wall shall be
judged as a level 3 damage.
There is a local change in the color of the cylinder. A local change in color may appear
on the surface of the cylinder that has been impacted. This change is caused by
delamination, cracks or crazes in the wrapping material, and scratches on the outer
surface. Cylinders showing signs of such damage shall be carefully inspected and
judged as a level 2 or level 3 damage.
Local surface cracking of gas cylinder. The impacted cylinders may develop circular,
oval or linear cracks on the surface of the wrapping material. This cracking can also
cause color changes. Cylinders showing signs of such damage shall be carefully
inspected and judged as a level 2 or level 3 damage.
Cylinders can be tested for impact damage by tapping with a coin. Use a one-yuan coin
to test areas that may have been damaged by impact. Hold the coin with hand. Tap the
surface of the wrapping layer with the edge of the coin. Listen carefully to the sound.
The sound produced by the impact-damaged area will be significantly different from
the sound produced by the non-damaged area.
6.3.8 Stress corrosion cracking
Stress corrosion cracking is the cracking or fracture of materials caused by a
combination of loads and harsh environments. Stress corrosion cracking in gas
cylinders can be caused by environmental induced erosion (such as carbonic acid or
acid leaking from auto parts). For gas cylinders using glass fiber as reinforcement fiber,
stress corrosion cracking shall be paid attention to.
Stress corrosion cracking on the wrapping layer appear as cracks or groups of cracks
perpendicular to the fiber direction. Cracks or groups of cracks perpendicular to the
fiber direction shall be judged as level 3 damages.
6.3.9 Crazing
Crazing is generally linear. Usually, crack occurs along the fiber direction, or crack
occurs in multiple directions on the resin on the surface of the wrapping layer. It can
occur after a cylinder has been pressurized a few times.
The crazing that the crack width along the fiber direction is less than 1.0mm, and there
is no corrosion of the metal material precipitated in the liner at the crack shall be judged
as a level 1 damage. The crazing that the crack width along the fiber direction is greater
than or equal to 1.0mm, or the corrosion of the metal material of the liner is precipitated
at the crack shall be judged as a level 3 damage.
6.4 Inspection and evaluation of metal part damage
6.4.1 Scratches, bruises, gouges and abrasions
The metal parts with scratch, bruise, gouge and abrasion marks shall be carefully
inspected to confirm that the residual wall thickness at the damage is not less than the
design wall thickness, otherwise it shall be judged as level 3 damage.
6.4.2 Bulge
A bulge is a serious damage. All cylinders showing signs of such damage shall be
classified as level 3 damage.
6.4.4 Concave
Small, shallow concaves are more of a concern than large, shallow concaves. Sharp
concaves can create stress concentrations and reduce the safety of the cylinder. A
concave with a depth greater than or equal to 1.6mm, or a maximum diameter or length
of less than or equal to 50mm, shall be judged as a level 3 damage.
7 Inspection and evaluation of cylinder thread
7.1 Visually inspect or use a low magnification magnifying glass to check the threads
one by one for cracks, deformation, corrosion or other mechanical damage.
7.2 There shall be no cracking defects in the thread of the cylinder mouth. However,
slight damage to the thread of the cylinder mouth that does not affect the use is allowed,
that is, not more than 2 teeth are allowed, and the length of the notch does not exceed
1/6 of the circumference, and the depth of the notch does not exceed 1/3 of the height
of the teeth.
7.3 For mild corrosion, abrasion or other damage to the cone thread of the cylinder
mouth, it can be repaired with a tap that meets the requirements of GB/T 10878. Use
the gauge that meets GB/T 8336 to inspect after repair. When the inspection result does
not meet the requirements of GB/T 8335, the gas cylinder shall be judged to be scrapped.
7.4 For mild corrosion, abrasion or other damage of the straight thread of the cylinder
mouth, it can be repaired with a tap that meets its corresponding standard. After repair,
use a gauge that meets its corresponding standard to inspect. When the inspection result
does not meet the requirements, the gas cylinder shall be judged to be scrapped.
8 Hydrostatic test
8.1 The hydrostatic test by external measurement method shall be carried out one by
one in accordance with GB/T 9251.
8.2 The test pressure is the water pressure test pressure in the cylinder mark.
8.3 The holding time of the gas cylinder under the hydrostatic test pressure shall not be
less than 2min.
8.4 During the hydrostatic test, the cylinders whose wrapping layer defects expand, the
cylinder body leaks, are obviously deformed, or the pressure drops back during the
pressure holding period (not caused by the leakage of the test device or the cylinder
mouth) shall be judged to be scrapped.
8.5 During the hydrostatic test, the volume residual deformation rate shall be measured
at the same time. Cylinders with a residual volumetric deformation rate exceeding 10%
shall be deemed to be scrapped.
8.6 During the hydrostatic test, when the pressure rises to 90% or more of the test
pressure, if the test cannot be continued for some reason, the test pressure shall be
increased by 0.7MPa during the test again but shall not exceed the self-tightening
pressure. At this time, the calculation of the residual deformation rate of the cylinder
volume shall be calculated according to the increased pressure. Retest only for once.
9 Internal drying
9.1 Drying method and requirements
9.1.1 Cylinders that have passed the hydrostatic test shall be internally dried one by one.
9.1.2 Hold the cylinder upside down for a while. After the remaining water in the
cylinder is drained, use dry air blowing, internal heating or other appropriate methods
for internal drying.
9.1.3 When drying inside, the temperature shall not exceed 65℃. The time shall be long
enough to keep the inside of the cylinder completely dry.
9.2 Drying condition inspection
Observe the dryness of the cylinder with the help of an endoscope or a small light bulb.
If the inner wall is completely dry, the cylinder valve and PRD end plug can be installed.
10 Cylinder valve inspection and assembly
10.1 The cylinder valve and PRD end plug shall be visually inspected one by one. All
parts of the cylinder valve and PRD end plug (bursting disc and fusible plug and so on)
shall be complete. There shall be no deformation. The thread shall not be damaged.
10.2 The cylinder valve and PRD end plug shall be firmly assembled and shall ensure
the effective thread number and sealing performance of their connection. A new seal
shall also be used when assembling straight-threaded cylinder valves and PRD end
plugs.
NOTE: The recommended upper valve torque of PZ27.8 taper thread is 200N·m~300N·m. The
recommended upper valve torque of M25×2.0-6H straight thread is 100N·m~130N·m.
10.3 When the cylinder valve or PRD end plug is damaged or cannot be used safely
until the next inspection cycle, the cylinder valve and PRD end plug shall be replaced
with a new one. The products of the same manufacturer and the same model as the
......
Source: Above contents are excerpted from the full-copy PDF -- translated/reviewed by: www.ChineseStandard.net / Wayne Zheng et al.
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