ISO 19882:2018

INTERNATIONAL ISO
STANDARD 19882
First edition
2018-11
Gaseous hydrogen — Thermally
activated pressure relief devices for
compressed hydrogen vehicle fuel
containers
Hydrogène gazeux — Dispositifs limiteurs de pression thermiquement
activés pour les conteneurs de carburant de véhicules à hydrogène
comprimé
Reference number
©
ISO 2018
© ISO 2018
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Published in Switzerland
ii © ISO 2018 – All rights reserved

Contents Page
Foreword .v
Introduction .vi
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 2
4 Service conditions . 3
4.1 General . 3
4.2 Design service life . 3
4.3 Nominal working pressure . 3
4.4 Durability test cycles . 3
4.5 Temperature range . 3
5 Quality assurance . 4
6 General requirements . 4
6.1 Material requirements. 4
6.2 Design requirements . 4
6.3 Flow capacity . 4
6.4 Rework and repair . 5
6.5 Failure modes and effects analysis (FMEA) . 5
7 Design qualification testing . 5
7.1 General . 5
7.2 Pressure cycling . 7
7.2.1 Sampling. 7
7.2.2 Procedure . 7
7.2.3 Acceptable results . 7
7.3 Accelerated life . 7
7.3.1 Sampling. 7
7.3.2 Procedure . 7
7.3.3 Acceptable results . 8
7.4 Thermal cycling . 8
7.4.1 Sampling. 8
7.4.2 Procedure . 8
7.4.3 Acceptable results . 8
7.5 Accelerated cyclic corrosion . 8
7.5.1 Sampling. 8
7.5.2 Procedure . 8
7.5.3 Acceptable results .11
7.6 Automotive fluids exposure .11
7.6.1 Sampling.11
7.6.2 Procedure .11
7.6.3 Acceptable results .11
7.7 Atmospheric exposure test .12
7.7.1 General.12
7.7.2 Oxygen aging .12
7.7.3 Ozone .12
7.8 Stress corrosion cracking resistance .12
7.8.1 Sampling.12
7.8.2 Procedure .12
7.8.3 Acceptable results .13
7.9 Impact due to drop and vibration .13
7.9.1 Impact due to drop .13
7.9.2 Vibration .13
7.10 Leakage .14
7.10.1 Sampling.14
7.10.2 Procedure .14
7.10.3 Acceptable results .14
7.11 Bench top activation .15
7.11.1 Sampling.15
7.11.2 Procedure .15
7.11.3 Acceptable results .15
7.12 Flow capacity .15
7.12.1 Sampling.15
7.12.2 Procedure .15
7.12.3 Acceptable results .16
7.13 High pressure activation and flow .16
7.13.1 Sampling.16
7.13.2 Procedure .16
7.13.3 Acceptable results .16
8 Inspection and acceptance testing .17
8.1 Inspection and acceptance testing plan .17
8.2 Inspector’s responsibilities .17
8.3 Inspection of system critical components .17
8.4 Leak testing .17
9 Production batch testing .17
9.1 General .17
9.2 Production batch sizes .17
9.2.1 General.17
9.2.2 Fusible materials.18
9.2.3 Pressure relief devices .18
9.3 Pressure relief device components .18
9.4 Thermal activation verification .18
9.4.1 General.18
9.4.2 High temperature soak .18
9.4.3 Activation .18
9.5 Pressure cycle verification .18
9.5.1 General.18
9.5.2 Procedure .18
9.5.3 Acceptable results .18
10 Marking .19
10.1 Required information .19
10.2 Marking methods .19
11 Component literature .19
Annex A (informative) Subsystem and vehicle level considerations .21
Annex B (informative) Design qualification test rationale .25
Bibliography .28
iv © ISO 2018 – All rights reserved

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.
The procedures used to develop this document and those intended for its further maintenance are
described in the ISO/IEC Directives, Part 1. In particular the different approval criteria needed for the
different types of ISO documents should be noted. This document was drafted in accordance with the
editorial rules of the ISO/IEC Directives, Part 2 (see www .iso .org/directives).
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. Details of
any patent rights identified during the development of the document will be in the Introduction and/or
on the ISO list of patent declarations received (see www .iso .org/patents).
Any trade name used in this document is information given for the convenience of users and does not
constitute an endorsement.
For an explanation on the voluntary nature of standards, the meaning of ISO specific terms and
expressions related to conformity assessment, as well as information about ISO's adherence to the
World Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT) see the following
URL: www .iso .org/iso/foreword .html.
This document was prepared by Technical Committee ISO/TC 197, Hydrogen technologies.
Any feedback or questions on this document should be directed to the user’s national standards body. A
complete listing of these bodies can be found at www .iso .org/members .html.
Introduction
The purpose of this document is to promote the implementation of hydrogen powered land vehicles
through the creation of performance based testing requirements for thermally activated pressure
relief devices for compressed hydrogen fuel containers. The successful commercialization of hydrogen
land vehicle technologies requires standards pertaining to fueling stations, vehicle fuel system
components and the global homologation of standards requirements for technologies with the same
end use. This will allow manufacturers to achieve economies of scale in production through the ability
to manufacture one product for global use.
This document is based on the CSA Standard ANSI/CSA HPRD 1-2013.
vi © ISO 2018 – All rights reserved

INTERNATIONAL STANDARD ISO 19882:2018(E)
Gaseous hydrogen — Thermally activated pressure relief
devices for compressed hydrogen vehicle fuel containers
1 Scope
This document establishes minimum requirements for pressure relief devices intended for use on
hydrogen fuelled vehicle fuel containers that comply with ISO 19881, IEC 62282-4-101, ANSI HGV 2,
CSA B51 Part 2, EC79/EU406, SAE J2579, or the UN GTR No. 13.
The scope of this document is limited to thermally activated pressure relief devices installed on fuel
containers used with fuel cell grade hydrogen according to SAE J2719 or ISO 14687 for fuel cell land
vehicles, and Grade A or better hydrogen according to ISO 14687 for internal combustion engine land
vehicles. This document also contains requirements for thermally activated pressure relief devices
acceptable for use on-board light duty vehicles, heavy duty vehicles and industrial powered trucks such
as forklifts and other material handling vehicles, as it pertains to UN GTR No. 13.
Pressure relief devices designed to comply with this document are intended to be used with high
quality hydrogen fuel such as fuel complying with SAE J2719 or ISO 14687 Type 1 Grade D.
Pressure relief devices can be of any design or manufacturing method that meets the requirements of
this document.
This document does not apply to reseating, resealing, or pressure activated devices.
Documents which apply to hydrogen fuel vehicles and hydrogen fuel subsystems include
IEC 62282- 4- 101, SAE J2578 and SAE J2579.
Annex A presents an informative record of recommended fuel container, fuel storage subsystem
and vehicle level requirements. The statements in Annex A are intended as recommendations for
consideration of inclusion by the organizations and committees developing standards on these sub
system and vehicle level standards.
Annex B presents a rationale for the design qualification tests in this document.
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 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 1431-1, Rubber, vulcanized or thermoplastic — Resistance to ozone cracking — Part 1: Static and
dynamic strain testing
ISO 6270-2, Paints and varnishes — Determination of resistance to humidity — Part 2: Condensation (in-
cabinet exposure with heated water reservoir)
1)
ISO 14687 , Hydrogen fuel quality — Product specification
ISO 19881, Gaseous hydrogen — Land vehicle fuel containers
ASTM D1149, Standard Test Method for Rubber Deterioration-Surface Ozone Cracking in a Chamber
ASTM D1193-06(R2011), Standard Specification for Reagent Water
1) To be published. Current stage 40.60
CSA ANSI HGV 2, Compressed hydrogen gas vehicle fuel containers
CSA B51-14, Boiler, Pressure Vessel, and Pressure Piping Code
EC79 (EU406), Type-approval of hydrogen-powered motor vehicles
SAE J2579: 2013, Standard for Fuel Systems in Fuel Cell and Other Hydrogen Vehicles
SAE J2719, Hydrogen Fuel Quality for Fuel Cell Vehicles
UN GTR No. 13, UN Global Technical Regulation on Hydrogen and Fuel Cell Vehicles
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https: //www .iso .org/obp
— IEC Electropedia: available at http: //www .electropedia .org/
3.1
flow capacity
capacity in volume per unit time at specified conditions
3.2
fusible material
metal, alloy, or other material capable of being melted by heat where the melting is integral to the
function of the pressure relief device (3.6)
3.3
manufacturer's specified activation temperature
temperature, as specified by the pressure relief device manufacturer, at which the pressure relief device
(3.6) is designed to release pressure
3.4
manufacturer's specified nominal working pressure
highest settled pressure at a uniform gas temperature of 15 °C of the container or container assembly
with which the pressure relief device (3.6) may be used, as specified by the pressure relief device
manufacturer
3.5
normal cubic centimeters
Ncc
dry gas that occupies a volume of 1 cm at a temperature of 273,15 K (0 °C) and an absolute pressure of
101,325 kPa
3.6
pressure relief device
device that, when activated under specified performance conditions, is used to vent the container
contents
Note 1 to entry: Reseating and resealing devices are not addressed by this document.
3.7
thermally activated pressure relief device
TPRD
pressure relief device (3.6) activated by temperature
2 © ISO 2018 – All rights reserved

4 Service conditions
4.1 General
Fuel containers may accidentally be exposed to fire or elevated temperature. These conditions may act
to increase the contained pressure or to degrade the structural materials, depending on the container
type and materials of construction. A pressure relief device provides a means to vent the fuel container
under these conditions.
A specific pressure relief device may not be suitable for all container types, sizes or installations. Fuel
container or installation standards may require that a pressure relief device be tested in conjunction
with other components.
CGA S1.1 states: “relief devices may not prevent burst of a cylinder under all conditions of fire exposure.
When the heat transferred to the cylinder is localized, intensive, and remote to the relief device, or
when the fire builds rapidly, such as in an explosion, and is of very high intensity, the cylinder can
weaken sufficiently to rupture before the relief device operates, or while it is operating”.
The following service conditions are representative of what can be seen in an automotive service.
These service conditions are provided as a basis for the design, manufacture, inspection and testing of
pressure relief devices which are used in compressed hydrogen vehicle fuel containers.
4.2 Design service life
The design service life of the pressure relief device shall be specified by the pressure relief device
manufacturer.
4.3 Nominal working pressure
This document applies to pressure relief devices that have a nominal working pressure, as specified
by the manufacturer, of 25 MPa, 35 MPa, 50 MPa or 70 MPa at 15 °C, hereinafter referred to in this
document as the following:
a) “H25” — 25 MPa;
b) “H35” — 35 MPa;
c) “H50” — 50 MPa;
d) “H70” — 70 MPa.
Other nominal working pressures for hydrogen gas besides those defined are allowed if the required
qualification test requirements of this document are met.
4.4 Durability test cycles
The design pressure cycles for pressure relief devices shall be between not more than 10 % of the
manufacturer's specified nominal working pressure and not less than 150 % of the manufacturer's
specified nominal working pressure for ten cycles and between not more than 10 % of the manufacturer's
specified nominal working pressure and not less than 125 % of the manufacturer's specified nominal
working pressure for 14 990 cycles.
NOTE The maximum pressure under the condition of fueling station dispenser fault management is 150 % of
the vehicle nominal working pressure, as defined in: SAE J2760, SAE J2579: 2013, Appendix A and CSA HGV 4.1.
4.5 Temperature range
The pressure relief device shall be designed to maintain pressure integrity from −40 °C to 85 °C.
5 Quality assurance
Quality system programs shall be established and operated to demonstrate that pressure relief devices
are produced in accordance with the qualified design.
6 General requirements
6.1 Material requirements
Materials normally in contact with hydrogen shall be determined to be acceptable in hydrogen service,
with the consideration of hydrogen embrittlement and hydrogen accelerated fatigue. The performance
tests cannot guarantee that all cases and conditions of the hydrogen service are validated, so it is still
incumbent on the designer/builder to carefully screen materials of construction for their intended
use. The materials and design shall be such that there is no significant change in the functioning of
the device, deformation or mechanical change in the device, and no harmful corrosion, deformation or
deterioration of the materials when subject to the service conditions given in Clause 4.
NOTE 1 Material performance data and/or acceptance criteria in hydrogen environments can be found in the
ISO 11114 series, the Sandia National Laboratory Technical Reference for Hydrogen Compatibility of Materials,
ANSI/AIAA G-095, ANSI/CSA CHMC 1, ASME B31.12, SAE J2579: 2013, Appendix B or in equivalent national
requirements.
NOTE 2 Some fusible alloys can contain heavy metals that can be considered environmentally unacceptable
by some customers and which can be prohibited by some jurisdictions.
Non-metallic materials normally in contact with hydrogen shall be verified to be acceptable in the
hydrogen service. Consideration shall be given to the fact that hydrogen diffuses through these materials
more easily than through metals; therefore the suitability of materials shall be verified. Non-metallic
materials shall retain their mechanical stability with respect to strength (fatigue properties, endurance
limit, creep strength) when exposed to the full range of service conditions and lifetime as specified by
the container manufacturer. Materials shall be sufficiently resistant to the chemical and physical action
of the fluids that they contain and to environmental degradation. The chemical and physical properties
necessary for operational safety shall not be significantly affected within the scheduled lifetime of the
equipment unless a replacement is foreseen; specifically, when selecting materials and manufacturing
methods, due account shall be taken of the material's corrosion and wear resistance, electrical
conductivity, impact strength, aging resistance, the effects of temperature variations, the effects arising
when materials are put together (for example, galvanic corrosion), the effects of ultraviolet radiation,
and to the degradation effects of hydrogen on the mechanical performance of a material.
6.2 Design requirements
The design shall be such that, once activated, the device fully vents the contents of the fuel container.
The design should minimize the possibility of external hazards (e.g. projectiles) resulting from
the activation of the device. Any material released shall not interfere with the proper venting of the
pressure relief device.
The pressure relief device shall be designed to address degradation from creep or plastic deformation.
The design or manufacturing process should account for the effects of material defects, particularly
casting and shrinkage voids, which adversely impact the robustness of the design.
6.3 Flow capacity
The flow capacity shall be indicated in the manufacturer’s published literature and verified by the flow
capacity test under 7.13.
The adequacy of the flow capacity of pressure relief devices for a given application shall be demonstrated
by bonfire testing in accordance with ISO 19881, ANSI HGV 2, CSA B51 Part 2, EC79/EU406, SAE J2579,
or the UN GTR No. 13 for fuel cell vehicles and by the minimization of the hazardous effects of the
4 © ISO 2018 – All rights reserved

pressure peaking phenomenon which can take place during high flow rate releases from small diameter
vents in enclosed spaces.
6.4 Rework and repair
New pressure relief devices that do not meet the requirements of this document may be reworked or
repaired as long as they satisfy the requirements of this document.
6.5 Failure modes and effects analysis (FMEA)
Design FMEA and Process FMEA shall be performed for pressure relief devices. The documents shall be
made available for review by fuel container or vehicle manufacturers upon request. A verification of the
existence of these documents satisfies the intent of this provision.
NOTE FMEA is a methodology used in the automotive industry to identify potentially hazardous failure
modes of safety devices and recommend changes in design, manufacturing, inspection or testing which eliminate
such failure modes or minimize their effects. FMEA is applied to both device design and to the manufacturing and
assembly process to identify corrective actions that improve device reliability and safety. Available references
include SAE J1739.
7 Design qualification testing
7.1 General
Design qualification testing shall be conducted on finished pressure relief devices that are representative
of the normal production. Test reports shall be kept on file by the pressure relief device manufacturer
and made available for review by fuel container manufacturers and end users upon request.
The design qualification testing required by this document shall, as appropriate and necessary,
be supplemented by additional tests defined in “design controls” or “recommended action” in the
Design FMEA.
Pressure relief devices representative of each design and design change shall be subjected to tests as
prescribed in Table 1. Designs which are sufficiently similar to an existing fully qualified design shall
be permitted to be qualified through a reduced test program as defined in Table 1. Design changes not
falling within the guidelines in Table 1 shall be qualified as original designs.
Any additional tests or requirements shall be performed in accordance with appropriate published
standards or procedures, as available.
Unless stated otherwise, the tests specified herein shall be conducted at an ambient temperature of
20 °C ± 5 °C.
Unless stated otherwise, the tests specified herein shall be conducted with the following tolerances on
specified pressures and temperatures:
Pressures 2 MPa or less: +0/−1 MPa
Pressures 125 % NWP or greater: +2 MPa/−0 MPa
Temperatures ±5 °C
Hydrogen used for testing shall be high quality hydrogen fuel, such as fuel meeting the requirements of
SAE J2719 or ISO 14687 Type 1 Grade D.
6 © ISO 2018 – All rights reserved
Table 1 — Test requirements for design and design changes
Manufacturer's Manufacturer's
Original Elastomeric Orifice Body mate- Surface Inlet connec- Outlet con-
ISO 19882 Tests specified nominal specified activa-
design seals size rial coating tion nection
working pressure tion temperature
7.2 Pressure cycling X X X X X X
7.3 Accelerated life X X X X X
7.4 Thermal cycling X X X X X
7.5 Accelerated cyclic
X X X X
corrosion
7.6 Automotive fluid
X X  X X
exposure
7.7 Atmospheric
X External only
exposure
7.8 Stress corrosion
X X  X X X
cracking resistance
7.9 Impact due to
X X X X X
drop & vibration
7.10 Leakage X X X X X X X X
7.11 Bench top acti-
X X X X X X X
vation
7.12 Flow capacity X X X X X
7.13 High pressure
X X X X X
activation and flow
NOTE  "X" requires physical testing.

7.2 Pressure cycling
7.2.1 Sampling
Five finished pressure relief devices shall be subjected to the pressure cycling test.
7.2.2 Procedure
Pressure cycling shall be performed in accordance with the following procedure:
At a sample temperature not less than 85 °C, the first 10 pressure cycles shall be from not greater
than 2 MPa to not less than 150 percent of the manufacturer's specified nominal working pressure
rating, followed by 2 240 pressure cycles from not greater than 2 MPa to not less than 125 percent
of the manufacturer's specified nominal working pressure, followed by 10 000 pressure cycles at a
sample temperature not less than 20 °C from not greater than 2 MPa to not less than 125 percent of
the manufacturer's specified nominal working pressure, followed by a final 2 750 pressure cycles at a
sample temperature not more than −40 °C from not greater than 2 MPa to not less than 80 percent of
the manufacturer's specified nominal working pressure. The pressure cycling shall be performed with
hydrogen gas at a rate not exceeding 10 cycles per minute.
Table 2 — Pressure cycling conditions
Pressure cycles Sample temperature
No. of cycles
to % for cycles
2 MPa to 150 % First 10 85 °C
2 MPa to 125 % Next 2 240 85 °C
2 MPa to 125 % Next 10 000 20 °C
2 MPa to 80 % Final 2 750 −40 °C
NOTE  All cycles are conducted at a rate not greater than 10 cycles per minute.
7.2.3 Acceptable results
Following the pressure cycling test, the pressure relief devices shall meet the requirements of 7.10, 7.11,
and 7.12.
7.3 Accelerated life
7.3.1 Sampling
a) Five finished pressure relief devices shall be subjected to the accelerated life test.
b) Three additional pressure relief devices shall be subjected to the manufacturer's specified
activation temperature until activation.
Pressure relief devices employing a glass bulb (thermobulb) or shape memory alloys (or other materials
that do not exhibit creep rupture phenomena) for activation are exempted from this Clause.
7.3.2 Procedure
Accelerated life testing shall be performed in accordance with the following procedure:
Pressure relief devices shall be placed in an oven or liquid bath with the temperature of the specimens
held constant within ±1 °C throughout the test. Pressure on the inlet of the devices shall be elevated to
125 % of the manufacturer's specified nominal working pressure and held constant within ±0,7 MPa.
The pressure supply may be located outside the controlled temperature oven or bath. The volume of
liquid or gas should be limited to prevent damage to the test apparatus upon activation and venting.
Each device may be pressurized individually or through a manifold system.
The accelerated life test temperature is T , given in °C by the expression:
L
0,503
TT=91, (1)
L
f
where T is the manufacturer's specified activation temperature in °C.
f
7.3.3 Acceptable results
a) The five pressure relief devices tested at their accelerated life test temperature shall not activate in
less than 500 h and shall meet the requirements of 7.10.
b) The three pressure relief devices tested at the manufacturer's specified activation temperature
shall activate in less than 10 h.
NOTE The 10 h time is to confirm conformance for the basis for Formula (1).
7.4 Thermal cycling
7.4.1 Sampling
One finished pressure relief device shall be subjected to the thermal cycling test.
7.4.2 Procedure
Thermal cycling shall be performed in accordance with the following procedure:
The pressure relief device shall be thermally cycled between 85 °C or higher and −40 °C or lower as
follows:
a) Place an unpressurized pressure relief device in a liquid bath maintained at −40 °C or lower for a
period of 2 h or more. Transfer to a liquid bath maintained at 85 °C or higher within 5 min.
b) Maintain the unpressurized pressure relief device in a liquid bath maintained at 85 °C or higher for
a period of 2 h or more. Transfer to a liquid bath maintained at −40 °C or lower within 5 min.
c) Repeat steps a) and b) until a total of 15 thermal cycles have been achieved.
d) With the pressure relief device conditioned for a minimum of 2 h in the −40 °C or lower liquid bath,
cycle the pressure relief device between not more than 10 % of the manufacturer's specified nominal
working pressure and not less than 80 % of the manufacturer's specified nominal working pressure
for a total of 100 cycles. The liquid bath shall be maintained at −40 °C or lower during this test.
When testing long trigger devices, the longest length permitted by the design shall be used for this test.
7.4.3 Acceptable results
Following the thermal and pressure cycling, the pressure relief device shall meet the requirements of
7.10 (except that the test shall be conducted at −40 °C or lower), 7.11, and 7.12.
7.5 Accelerated cyclic corrosion
7.5.1 Sampling
Three finished pressure relief devices shall be subjected to the accelerated cyclic corrosion test.
7.5.2 Procedure
Accelerated cyclic corrosion shall be performed in accordance with the following procedure:
8 © ISO 2018 – All rights reserved

The pressure relief devices shall be exposed to an accelerated laboratory corrosion test, under
a combination of cyclic conditions (salt solution, various temperatures, humidity, and ambient
environment). The test method is comprised of 1 % (approximate) complex salt mist applications
coupled with high temperature, high humidity and high temperature dry off. One (1) test cycle is equal
to 24 h, as illustrated in Figure 1.
The apparatus used for this test shall consist of a fog/environmental chamber, suitable water supply
conforming to ASTM D1193 Type IV, provisions for heating the chamber and the necessary means
of controlling the temperature between 22 °C and 62 °C. The apparatus shall include provisions for
a supply of suitably conditioned compressed air and one or more nozzles for fog generation. The
nozzle or nozzles used for the generation of the fog shall be directed or baffled to minimize any direct
impingement on the test samples.
The apparatus shall consist of the chamber design as defined in ISO 6270-2. During “wet-bottom”
generated humidity cycles, the testing agency shall confirm that visible water droplets are found on the
samples to verify proper wetness.
Steam generated humidity may be used provided the source of water used in generating the steam is
free of corrosio
...