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INTERNATIONAL ISO
STANDARD 9809-1

Second edition
2010-04-15

Gas cylinders — Refillable seamless steel

gas cylinders — Design, construction and
testing —
Part 1:
Quenched and tempered steel cylinders
with tensile strength less than 1 100 MPa
Bouteilles à gaz — Bouteilles à gaz rechargeables en acier sans
soudure — Conception, construction et essais —
Partie 1: Bouteilles en acier trempé et revenu ayant une résistance à la
traction inférieure à 1 100 MPa

Reference number
ISO 9809-1:2010(E)

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ISO 9809-1:2010(E)

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ISO 9809-1:2010(E)

Contents Page

Foreword ............................................................................................................................................................iv
Introduction.........................................................................................................................................................v
1 Scope ......................................................................................................................................................1
2 Normative references............................................................................................................................1
3 Terms and definitions ...........................................................................................................................2
4 Symbols..................................................................................................................................................2
5 Inspection and testing ..........................................................................................................................3
6 Materials .................................................................................................................................................4
7 Design.....................................................................................................................................................7
8 Construction and workmanship ........................................................................................................11
9 Type approval procedure....................................................................................................................13
10 Batch tests ...........................................................................................................................................15
11 Tests/examinations on every cylinder ..............................................................................................24
12 Certification..........................................................................................................................................25
13 Marking .................................................................................................................................................25
Annex A (informative) Description and evaluation of manufacturing imperfections and conditions
for rejection of seamless steel gas cylinders at time of final inspection by the
manufacturer........................................................................................................................................26
Annex B (normative) Ultrasonic examination ................................................................................................32
Annex C (informative) Type approval certificate ...........................................................................................38
Annex D (informative) Acceptance certificate................................................................................................39
Bibliography......................................................................................................................................................41

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ISO 9809-1:2010(E)

Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies
(ISO member bodies). The work of preparing International Standards is normally carried out through ISO
technical committees. Each member body interested in a subject for which a technical committee has been
established has the right to be represented on that committee. International organizations, governmental and
non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely with the
International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization.

International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2.

The main task of technical committees is to prepare International Standards. Draft International Standards
adopted by the technical committees are circulated to the member bodies for voting. Publication as an
International Standard requires approval by at least 75 % of the member bodies casting a vote.

Attention is drawn to the possibility that some of the elements of this document may be the subject of patent
rights. ISO shall not be held responsible for identifying any or all such patent rights.

ISO 9809-1 was prepared by Technical Committee ISO/TC 58, Gas cylinders, Subcommittee SC 3, Cylinder
design.

This second edition cancels and replaces the first edition (ISO 9809-1:1999), which has been technically
revised by the following:

a) the reduction of maximum sulfur content in 6.2.2 from 0,020 % to 0,010 %, which is now applicable to all
strength levels;

b) the note in 7.3 regarding limitation of the F factor was deleted (as required by the United Nations
Recommendations on the Transport of Dangerous Goods: Model Regulations);

c) the modification of provisions for ultrasonic examination in 8.4 to include ultrasonic examination on the
cylindrical area to be closed, prior to the forming process;

d) the addition of the requirement of a base check according to 9.2.3 for all cylinder types during prototype
testing;

e) the addition of the requirement of a base check according to 9.2.3 for cylinders made from continuously
cast billet material during batch testing.

ISO 9809 consists of the following parts, under the general title Gas cylinders — Refillable seamless steel gas
cylinders — Design, construction and testing:

⎯ Part 1: Quenched and tempered steel cylinders with tensile strength less than 1 100 MPa

⎯ Part 2: Quenched and tempered steel cylinders with tensile strength greater than or equal to 1 100 MPa

⎯ Part 3: Normalized steel cylinders

Stainless steel cylinders with tensile strength of less than 1 100 MPa will form the subject of a Part 4.

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ISO 9809-1:2010(E)

Introduction
This part of ISO 9809 provides a specification for the design, manufacture, inspection and testing of a
seamless steel cylinder for worldwide usage. The objective is to balance design and economic efficiency
against international acceptance and universal utility.

ISO 9809 (all parts) aims to eliminate existing concerns about climate, duplicate inspections and restrictions
because of a lack of definitive International Standards. This part of ISO 9809 should not be construed as
reflecting on the suitability of the practice of any nation or region.

This part of ISO 9809 addresses the general requirements on design, construction and initial inspection and
testing of pressure receptacles of the United Nations Recommendations on the Transport of Dangerous
Goods: Model Regulations.

It is intended to be used under a variety of regulatory regimes, but is suitable for use with the conformity
assessment system in 6.2.2.5 of the above-mentioned Model Regulations.

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INTERNATIONAL STANDARD ISO 9809-1:2010(E)

Gas cylinders — Refillable seamless steel gas cylinders —

Design, construction and testing —
Part 1:
Quenched and tempered steel cylinders with tensile strength
less than 1 100 MPa

1 Scope
This part of ISO 9809 specifies minimum requirements for the material, design, construction and workmanship,
manufacturing processes, examination and testing at manufacture of refillable quenched and tempered
seamless steel gas cylinders of water capacities from 0,5 l up to and including 150 l for compressed, liquefied
and dissolved gases. This part of ISO 9809 is applicable to cylinders with a maximum actual tensile strength
Rma of less than 1 100 MPa.

NOTE 1 If desired, cylinders of water capacity less than 0,5 l and between 150 l and 500 l can be manufactured and
certified to be in compliance with this part of ISO 9809.

NOTE 2 For quenched and tempered steel cylinders with maximum tensile strength greater than or equal to 1 100 MPa,
see ISO 9809-2. For normalized steel cylinders, see ISO 9809-3.

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.

ISO 148-1, Metallic materials — Charpy pendulum impact test — Part 1: Test method

ISO 6506-1, Metallic materials — Brinell hardness test — Part 1: Test method

ISO 6508-1, Metallic materials — Rockwell hardness test — Part 1: Test method (scales A, B, C, D, E, F, G, H,
K, N, T)

ISO 6892-1, Metallic materials — Tensile testing — Part 1: Method of test at room temperature

ISO 7438, Metallic materials — Bend test

ISO 9329-1, Seamless steel tubes for pressure purposes — Technical delivery conditions — Part 1: Unalloyed
steels with specified room temperature properties

ISO 9712, Non-destructive testing — Qualification and certification of personnel

ISO 11114-1, Transportable gas cylinders — Compatibility of cylinder and valve materials with gas
contents — Part 1: Metallic materials

ISO 11114-4, Transportable gas cylinders — Compatibility of cylinder and valve materials with gas
contents — Part 4: Test methods for selecting metallic materials resistant to hydrogen embrittlement

ISO 13769, Gas cylinders — Stamp marking

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ISO 9809-1:2010(E)

3 Terms and definitions

For the purposes of this document, the following terms and definitions apply.

3.1
batch
quantity of up to 200 cylinders plus cylinders for destructive testing of the same nominal diameter, thickness,
length and design made successively on the same equipment, from the same cast of steel and subjected to
the same heat treatment for the same duration of time

3.2
burst pressure
pb
highest pressure reached in a cylinder during a burst test

3.3
design stress factor
F
ratio of equivalent wall stress at test pressure, ph, to guaranteed minimum yield strength, Reg

3.4
quenching
hardening heat treatment in which a cylinder, which has been heated to a uniform temperature above the
upper critical point, Ac3, of the steel, is cooled rapidly in a suitable medium

3.5
tempering
toughening heat treatment which follows quenching, in which the cylinder is heated to a uniform temperature
below the lower critical point, Ac1, of the steel

3.6
test pressure
ph
required pressure applied during a pressure test

NOTE It is used for cylinder wall thickness calculation.

3.7
working pressure
settled pressure of a compressed gas at a uniform reference temperature of 15 °C in a full gas cylinder

3.8
yield strength
stress value corresponding to the upper yield strength, ReH, or for steels which do not exhibit a defined yield,
the 0,2 % proof strength (non-proportional extension), Rp0,2

See ISO 6892-1.

4 Symbols
a Calculated minimum thickness, in millimetres, of the cylindrical shell

a′ Guaranteed minimum thickness, in millimetres, of the cylindrical shell

a1 Guaranteed minimum thickness, in millimetres, of a concave base at the knuckle (see Figure 2)

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ISO 9809-1:2010(E)

a2 Guaranteed minimum thickness, in millimetres, at the centre of a concave base (see Figure 2)

A Percentage elongation after fracture

b Guaranteed minimum thickness, in millimetres, at the centre of a convex base (see Figure 1)

c Maximum permissible deviation of burst profile, in millimetres (see Figures 10 and 11)

D Nominal outside diameter of the cylinder, in millimetres (see Figure 1)

Df Diameter, in millimetres, of former (see Figure 6)

F Design stress factor (variable) (see 3.3)

h Outside depth (concave base end), in millimetres (see Figure 2)

H Outside height, in millimetres, of domed part (convex head or base end) (see Figure 1)

Lo Original gauge length, in millimetres, as defined in ISO 6892-1 (see Figure 5)

N Ratio of the diameter of the bend test former to actual thickness of test piece, t

pb Measured burst pressure, in bars1), above atmospheric pressure

Ph Hydraulic test pressure, in bars, above atmospheric pressure

Py Observed pressure when cylinder starts yielding during hydraulic burst test, in bars, above atmospheric
pressure

r Inside knuckle radius, in millimetres (see Figures 1 and 2)

Reg Minimum guaranteed value of the yield strength (see 7.1.1), in megapascals, for the finished cylinder

Rea Actual value of the yield strength, in megapascals, as determined by the tensile test (see 10.2)

Rmg Minimum guaranteed value of the tensile strength, in megapascals, for the finished cylinder

Rma Actual value of tensile strength, in megapascals, as determined by the tensile test (see 10.2)

So Original cross-sectional area of tensile test piece, in square millimetres, in accordance with ISO 6892-1

t Actual thickness of the test specimen, in millimetres

tm average cylinder wall thickness at position of testing during the flattening test, in millimetres

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 Figure 5)

5 Inspection and testing

NOTE Evaluation of conformity can be carried out according to the regulations recognized by the country(ies) in
which the cylinders are intended to be used.

1) 1 bar = 105 Pa = 105 N/m2.

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ISO 9809-1:2010(E)

To ensure that the cylinders conform to this part of ISO 9809, they shall be subject to inspection and testing in
accordance with Clauses 9, 10 and 11 by an inspection body (hereinafter referred to as "the inspector")
authorized to do so.

Equipment used for measurement, testing and examination during production shall be maintained and
calibrated within a documented quality management system.

6 Materials

6.1 General requirements

6.1.1 Materials for the manufacture of gas 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 6.3 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 material to be used for making cylinders (see 9.2.3).

6.2 Controls on chemical composition

6.2.1 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;

⎯ the maximum sulfur and phosphorus contents in all cases.

The carbon, manganese and silicon contents and, where appropriate, the chromium, nickel and molybdenum
contents shall be given, with tolerances, such that the differences between the maximum and minimum values
of the cast do not exceed the values shown in Table 1.

The combined content of the following elements: vanadium, niobium, titanium, boron and zirconium shall not
exceed 0,15 %.

The actual content of any element deliberately added shall be reported and their maximum content shall be
representative of good steel making practice.

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ISO 9809-1:2010(E)

Table 1 — Chemical composition tolerances

Element Maximum content Permissible range

(mass fraction) (mass fraction)
% %
Carbon < 0,30 % 0,06
W 0,30 % 0,07
Manganese All values 0,30
Silicon All values 0,30
Chromium < 1,50 % 0,30
W 1,50 % 0,50
Nickel All values 0,40
Molybdenum All values 0,15

6.2.2 Sulfur and phosphorus in the cast analysis of material used for the manufacture of gas cylinders shall
not exceed the values shown in Table 2.

Table 2 — Maximum sulfur and phosphorus limits in % (mass fraction)

Sulfur 0,010
Phosphorus 0,020
Sulfur and phosphorus 0,025

6.2.3 The cylinder manufacturer shall obtain and make available certificates of cast (heat) analyses of the
steels supplied for the construction of gas cylinders.

Should check analyses be required, they shall be carried out either on specimens taken during manufacture
from the material in the form as supplied by the steel maker to the cylinder manufacturer or from finished
cylinders. In any check analysis, the maximum permissible deviation from the limits specified for the cast
analyses shall conform to the values specified in ISO 9329-1.

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 specified in 6.2.1, are given in Table 3.

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