INTERNATIONAL ISO
STANDARD 16964
Second edition
2019-01
Gas cylinders — Flexible hoses
assemblies — Specification and testing
Bouteilles à gaz — Flexibles — Spécifications et essais
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ISO 16964:2019
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Reference number
ISO 16964:2019(E)
© ISO 2019
ISO 16964:2019(E)
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ISO 16964:2019
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ISO 16964:2019(E)
Contents Page
Foreword......................................................................................................................................................................................................................................... iv
Introduction...................................................................................................................................................................................................................................v
1 Scope.................................................................................................................................................................................................................................. 1
2 Normative references....................................................................................................................................................................................... 1
3 Terms and definitions...................................................................................................................................................................................... 1
4 Requirements........................................................................................................................................................................................................... 2
4.1 Production pressure tests.............................................................................................................................................................. 2
4.1.1 Strength test.......................................................................................................................................................................... 2
4.1.2 Leak test................................................................................................................................................................................... 2
4.2 Type tests...................................................................................................................................................................................................... 2
4.2.1 General...................................................................................................................................................................................... 2
4.2.2 Burst pressure test (3 samples per type).................................................................................................... 3
4.2.3 Pressure cycle test (3 samples per type)..................................................................................................... 3
4.2.4 Oxygen compatibility test (3 samples per type)................................................................................... 4
4.2.5 Acetylene compatibility test (3 samples).................................................................................................... 4
4.2.6 Gas material compatibility....................................................................................................................................... 4
4.2.7 Test of the safety cable (2 samples)................................................................................................................. 4
4.2.8 Additional tests.................................................................................................................................................................. 5
5 Marking........................................................................................................................................................................................................................... 6
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Annex A (informative) Examples of kink test, side impact test and torsion test..................................................... 7
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Bibliography.............................................................................................................................................................................................................................. 14
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ISO 16964:2019(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.
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 of 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
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This document was prepared by Technical Committee ISO/TC 58, Gas cylinders, Subcommittee SC 2,
Cylinder fittings. ISO 16964:2019
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This second edition cancels and replaces the first edition (ISO 16964:2015), which has been technically
f3ec43396571/iso-16964-2019
revised.
The main changes compared to the previous edition are as follows:
— Test 1 for the safety cable has been clarified;
— the leak test has been corrected;
— the pressure cycle test has been clarified;
— the test apparatus for the torsion test, as shown in Figures A.6 and A.7 has been clarified.
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.
iv © ISO 2019 – All rights reserved
ISO 16964:2019(E)
Introduction
Flexible hose assemblies are used to transfer industrial and medical gases into cylinders, bundles,
MEGCs and trailers (battery vehicles), and also to supply such gases to user equipment.
There is a range of existing International Standards to be used for specific applications or hose
construction:
— ISO 14113 which covers hoses made with internal rubber or plastics tubing and used to supply gases
to customers for welding applications;
— ISO 21969 which covers hoses with an internal corrugated metallic liner and used to supply medical
gases to customers;
— ISO 10380 which covers hoses with internal corrugated metallic liner for all applications including
non-industrial and medical gases.
ISO 14113 and ISO 21969 cover only specific customer applications and are intended to be used
accordingly, while ISO 10380 is general in its approach.
The intent of the document is to describe flexible hoses not defined in the specific applications
documents mentioned above.
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INTERNATIONAL STANDARD ISO 16964:2019(E)
Gas cylinders — Flexible hoses assemblies — Specification
and testing
1 Scope
This document provides specification and testing requirements for high pressure flexible hose
assemblies intended to be connected to gas cylinders, bundles of cylinders or trailers (battery vehicles),
and MEGCs for use when filling and emptying gas at production sites and also for customer use. This
document applies to flexible hose assemblies with rated pressures up to 1 000 bar for use in the
temperature range of −40 °C to +65 °C.
This document is not applicable to:
— rubber and plastics flexible hose assemblies for welding, cutting and related processes up to 45 MPa
(450 bar) for customer use (see ISO 14113);
— high pressure flexible hose assemblies for use with medical gas systems for customer use (see
ISO 21969);
— low pressure hose assemblies for use with medical gases for customer use (see ISO 5359);
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— rubber and thermoplastic low pressure hose assemblies for welding, cutting and related processes
for customer use (see ISO 3821 or ISO 12170);
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— flexible hose assemblies for cryogenic applications (see ISO 21012);
ISO 16964:2019
— flexible hose assemblies for liquid petroleum gas (LPG).
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NOTE Flexible hose assembly designs which pass the type test approval described in this document can
have a lower ratio of burst pressure to rated pressure than stated in other standards.
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 148-1, Metallic materials — Charpy pendulum impact test — Part 1: Test method
ISO 10286, Gas cylinders — Terminology
ISO 10380, Pipework — Corrugated metal hoses and hose assemblies
ISO 14113:2013, Gas welding equipment — Rubber and plastics hose and hose assemblies for use with
industrial gases up to 450 bar (45 MPa)
ISO 21969:2009, High-pressure flexible connections for use with medical gas systems
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO 10286 and the following 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
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ISO 16964:2019(E)
— IEC Electropedia: available at http://www.electropedia.org/
3.1
rated pressure
PR
pressure of a hose assembly equal to 1,25 PW, PW being the working pressure of the cylinder as defined
in ISO 10286
Note 1 to entry: National and international design codes for pressure systems can specify a higher value of rated
pressure.
Note 2 to entry: When cylinders are used (e.g. during filling or product withdrawal), the gas temperature can be
higher than 15 °C. This is the reason why the rated pressure is higher than the cylinder working pressure.
3.2
burst pressure
highest pressure reached in a flexible hose assembly during a burst test
4 Requirements
4.1 Production pressure tests
4.1.1 Strength test
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Each flexible hose assembly shall first be subjected to a strength test using oil-free water at a pressure
at least equal to 1,5 times the rated pressure, PR, for a minimum of 3 min. There shall be no visible
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sign of leakage, permanent deformation or other sign of failure. Where hydraulic testing would result
in unacceptable contamination of the flexible hose assembly, the hydraulic test may be replaced by
a pneumatic test using a compatible medium such as dry oil-free air or nitrogen. Appropriate safety
ISO 16964:2019
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protect personnel and equipment during testing.
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4.1.2 Leak test
Each hose or hose assembly shall be tested for leakage, e.g. by total immersion in water for 3 min at
ambient temperature, at a test pressure equal to the PR, except for acetylene where the test pressure
shall be no less than 300 bar.
Hose or hose assemblies to be used with hydrogen or helium shall be tested with helium. Hose or hose
assemblies to be used with other gases shall be tested with a compatible medium such as dry oil-free
air or nitrogen.
The leak rate shall be less than 15 cm3/h.
4.2 Type tests
4.2.1 General
All test samples shall be manufactured to the same design, material specification and from the same
batch of raw material. Records of the tests performed are to be retained by the flexible hose assembly
manufacturer.
To carry out the tests described in this document, it is recommended that the nominal length of hose
between end fittings be 1 000 mm unless otherwise specified.
Before being type tested, all sample flexible hose assemblies shall be subjected to production pressure
tests as specified in 4.1.
For hoses to be used in hydrogen or helium service, the leak test in 4.1.2 shall be carried out using helium.
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ISO 16964:2019(E)
Tests shall be performed at ambient temperature.
4.2.2 Burst pressure test (3 samples per type)
The flexible hose assembly complete with safety cable and clamps (if applicable), is to be hydraulically
pressurized until burst occurs. The pressurization rate shall be adjusted at the beginning of the test to
be approximately constant and to reach the burst pressure in not less than 1 min.
For specific applications, hold steps may be required before final burst pressure is reached.
The burst pressure of the flexible hoses assemblies shall not be less than 3 × PR for a value of PR less
than 480 bar and [(2 × PR) + 480] bar for a value of PR greater than or equal to 480 bar.
NOTE For acetylene service, hose with a higher burst pressure can be necessary in order to pass the
decomposition test described in 4.2.5 for acetylene flexible hose assemblies. The minimum burst pressure for
this type of hose is generally given by the hose manufacturer.
4.2.3 Pressure cycle test (3 samples per type)
4.2.3.1 General
The flexible hose assembly complete with safety cable and clamps (if applicable) shall be submitted to a
hydraulic pressurization endurance test from a nominal atmospheric pressure (5 bar maximum) to PR
at a frequency of no more than 30 cycles per minute.
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A pressure cycle consists of a pressure increase starting from a pressure not more than 5 bar to PR and
a pressure decrease from PR back to the start condition.
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This endurance test shall not apply to acetylene flexible hose assemblies because the construction
of these hoses is designed to resist extremely high pressure and stress compared to acetylene’s low
ISO 16964:2019
working pressure PW.
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4.2.3.2 General requirement
It shall be checked that the entire flexible hose assembly is exposed to a pressure cycle where:
— the maximum pressure is PR; and
— the minimum of each pressure cycle is no more than 5 bar.
The flexible hose assemblies shall not burst or show any visible leak during the test:
— Category A: 5 000 pressure cycles for flexible hose assemblies dedicated to non-filling applications
such as customer installations. This applies to flexible hose assemblies with metallic and non-
metallic liners.
— Category B: 50 000 pressure cycles for flexible hose assemblies with non-metallic liners dedicated
to filling centres.
Due to expansion of the hose during the test, the hydraulic pressure can fall. However, the hydraulic
pressure shall never fall below PR.
Care should be taken to avoid hose bending during testing as this can reduce the cycle life. The position
of the hose during the cycle test should be recorded (e.g. pictures).
4.2.3.3 Specific requirements for metallic hoses used in filling centres
The pressure cycle test shall be performed on hose assemblies with a maximum of 50 000 cycles. No
failure should occur before 10 000 cycles.
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ISO 16964:2019(E)
A leak is accepted above 10 000 cycles but, in such cases, the life of the hose shall be limited
proportionally to its performance in this hydraulic pressure cycling test.
Hoses not able to pass the 10 000 pressure cycles minimum requirement, but demonstrating by this
test a non-hazardous failure mode, can be used in service following risk assessment provided that the
risk assessment includes as a minimum:
— the definition of a specific application;
— the mode of failure of the hose and any mitigation;
— the associated risk created by the escape of gas;
— the protection of personnel.
Following such risk assessment, the life span for the hose can be determined (e.g. use for a given time or
until the flexible hose assembly leaks).
If the test has been completed before any leak has been detected (e.g. after 50 000 cycles), then the
flexible hose assembly shall be pressurized at PR with compressed dry oil-free air or nitrogen to check
for leaks. The leak rate shall be less than 15 cm3/h. For hoses to be used in hydrogen or helium service,
the leak test shall be carried out using helium.
4.2.4 Oxygen compatibility test (3 samples per type)
This test shall be performed for all oxygen applications. Follow the procedure given in
ISO 21969:2009, 6.2.4. iTeh STANDARD PREVIEW
4.2.5
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Acetylene compatibility test (3 samples)
This test shall be performed for all acetylene applications. Follow the procedure given in
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Flexible hose assemblies passing this test shall be marked to identify they are suitable for acetylene
service e.g. “C2H2” or as specified by ISO 14113.
4.2.6 Gas material compatibility
All materials in contact with the gases shall be compatible within the intended pressure and temperature
range of the gas application. For guidance, use the requirements of ISO 11114-1 and ISO 11114-2 as
applicable.
4.2.7 Test of the safety cable (2 samples)
4.2.7.1 General
This test shall be performed if the flexible hose assembly is equipped with a safety cable. For safety
reasons, it is recommended to perform this test in a cage to protect personnel. The hose and the cable
shall be fixed. The distance between the horizontal fixed points of the hose ends shall be equal to 75 %
of the hose length so that the hose has a gentle bend and is not tight between the fixed points.
If the safety cable is designed to be anchored separately to the hose end fitting, cable ends shall be
anchored as they would be in customer use. If not otherwise specified, the safety cable shall be fixed as
per the instructions for use.
If hose end fittings are not of the same design (are not identical), the manufacturer shall indicate the
upstream fitting the gas will be put through during the test.
The downstream fixed point of the flexible hose shall be plugged.
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ISO 16964:2019(E)
4.2.7.2 Test 1
The flexible hose assembly is severed by drilling a hole at mid-length on one side without damaging
the safety cable or disturbing the clamps. The diameter of the drilled hole shall be equal to 80 % of
the internal nominal diameter, DN, of the flexible hose assembly. Air or nitrogen is admitted at PR
via a quick opening valve into the hose through one of the end fittings while the other end is open to
atmosphere. The gas supplied is cut off not less than 10 s after opening. The cable and its fixings shall
be intact and the clamps shall have remained in their original positions on the hose. Their location is
recorded before and after testing. The clamps shall remain fixed on the cable but their location can be
different. A movement of ±2,5 cm along the hose is accepted.
4.2.7.3 Test 2
A similar test is performed if the safety cable is secured to the hose end fittings. In this case, the flexible
hose assembly is severed by drilling the same size hole as in Test 1 but immediately adjacent to the end
fitting at the opposite end of the hose to where the test gas is admitted. The same acceptance criteria as
in Test 1 shall be used.
If the safety cable is designed to be anchored separately to the hose end fitting, the test is performed
with the same requirements and acceptance criteria as above but with the end adjacent to the drilling
plugged and not anchored.
The plug (mass and dimensions) should be recorded in the report.
4.2.8 Additional tests
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4.2.8.1 General (standards.iteh.ai)
These tests (see Annex A) are part of the type tests when listed as mandatory in 4.2.8.2 to 4.2.8.7.
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4.2.8.2 Kink test (1 sample) f3ec43396571/iso-16964-2019
This test (see A.1) is mandatory for non-metallic lined flexible hose assemblies except when other kink
prevention safety measures are in place (e.g. external spring protection).
NOTE This test is normally performed by the hose manufacturer, and not necessarily by the hose assembly
manufacturer.
With the flexible hose assembly configured with a single loop midway along its length, and with one
end connection secured, a longitudinal tensile force shall be applied to the opposite end to create a
localized bend and flattening. The tensile force is increased until the cross-section of the hose becomes
oval and the shortest cross-sectional dimension is 75 % of the original external diameter. This force
shall be recorded. When it is completed, a hydraulic pressure of PR shall be applied and there shall be
no leakage evident.
4.2.8.3 Side impact test (1 sample)
This test (see A.2) is mandatory for non-metallic lined flexible hose assemblies with copper alloys
or with low impact strength material end fittings except when other side impact prevention safety
measures are in place (e.g. external spring protection).
The flexible hose assembly is fixed as specified in A.2.3.3. The impact energy is created with a knife
edge impact tool to determine the absorbed energy for failure. Any rupture or crack is classed as a
failure. This test shall be repeated at the other extremity (if different) to find the weakest side. The
impact energies of both ends should be recorded.
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