Transportable gas cylinders Periodic inspection and maintenance of dissolved acetylene cylinders

Transcription

1 BRITISH STANDARD BS EN 12863:2002 Incorporating Amendment No. 1 Transportable gas cylinders Periodic inspection and maintenance of dissolved acetylene cylinders The European Standard EN 12863:2002, with the incorporation of amendment A1:2005, has the status of a British Standard ICS

2 BS EN 12863:2002 National foreword This British Standard is the official English language version of EN 12863:2002, including amendment A1:2005. It supersedes BS 6071:1981 which is withdrawn. The UK participation in its preparation was entrusted by Technical Committee PVE/3, Gas containers, to Subcommittee PVE/3/7, Gas cylinder (receptacle) operations, which has the responsibility to: aid enquirers to understand the text; present to the responsible international/european committee any enquiries on the interpretation, or proposals for change, and keep the UK interests informed; monitor related international and European developments and promulgate them in the UK. A list of organizations represented on this subcommittee can be obtained on request to its secretary. Cross-references The British Standards which implement international or European publications referred to in this document may be found in the BSI Catalogue under the section entitled International Standards Correspondence Index, or by using the Search facility of the BSI Electronic Catalogue or of British Standards Online. This publication does not purport to include all the necessary provisions of a contract. Users are responsible for its correct application. Compliance with a British Standard does not of itself confer immunity from legal obligations. This British Standard, having been prepared under the direction of the Engineering Sector Policy and Strategy Committee, was published under the authority of the Standards Policy and Strategy Committee on 9 August 2002 Summary of pages This document comprises a front cover, an inside front cover, the EN title page, pages 2 to 26 and a back cover. The BSI copyright date displayed in this document indicates when the document was last issued. Amendments issued since publication Amd. No. Date Comments BSI August August 2006 Replacement of text in and addition of new Annex F ISBN

3 EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM EN June A1 November 2005 ICS English version Transportable gas cylinders - Periodic inspection and maintenance of dissolved acetylene cylinders Bouteilles à gaz transportables - Contrôle et entretien périodiques des bouteilles d'acétylène dissous Ortsbewegliche Gasflaschen - Wiederkehrende Prüfung und Instandhaltung von Gasflaschen für gelöstes Acetylen This European Standard was approved by CEN on 6 March CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the Management Centre or to any CEN member. This European Standard exists in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the Management Centre has the same status as the official versions. CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom. EUROPEAN COMMITTEE FOR STANDARDIZATION COMITÉ EUROPÉEN DE NORMALISATION EUROPÄISCHES KOMITEE FÜR NORMUNG Management Centre: rue de Stassart, 36 B-1050 BRUSSELS 2002 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members. Ref. No. EN 12863:2002 E

4 Contents Foreword... 3 Introduction Scope Normative references Terms and definitions General Preparation of gas cylinder Inspection and maintenance Identification of content Markings Records Disposal of unserviceable cylinders Annex A (informative) Acetylene cylinders manufactured according to National Regulations Annex B (informative) Procedure to be adopted when a cylinder valve is suspected to be obstructed Annex C (normative) Description, evaluation of defects and conditions for rejection of acetylene gas cylinders at time of visual inspection Annex D (informative) Tools and clearance gauges and diagrammatic illustration of the top of (monolithic and non-monolithic) acetylene cylinders Annex E (informative) Inspection and maintenance of valves and their connections Annex F (normatuve) Cracks on porous masses Bibliography page 2

5 Foreword This document EN 12863:2002 has been prepared by Technical Committee CEN/TC 23 "Transportable gas cylinders", the secretariat of which is held by BSI. This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by December 2002, and conflicting national standards shall be withdrawn at the latest by December This European Standard has been submitted for reference into the RID and/or in the technical annexes of the ADR. Therefore in this context the standards listed in the normative references and covering basic requirements of the RID/ADR not addressed within the present standard are normative only when the standards themselves are referred to in the RID and/or in the technical annexes of the ADR. In this standard the annexes A, B, D and E are informative. Annex C is normative. According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and the United Kingdom. Foreword to amendment A1 This European Standard (EN 12863:2002/A1:2005) has been prepared by Technical Committee CEN/TC 23 "Transportable gas cylinders", the secretariat of which is held by BSI. This Amendment to the European Standard EN 12863:2002 shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by May 2006 and conflicting national standards shall be withdrawn at the latest by May According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuvania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Slovakia, Slovenia, Spain, Sweden, Switzerland and the United Kingdom. 3

6 Introduction Acetylene cylinders differ from all other cylinders transporting compressed or liquefied gases because they contain a porous mass and normally a solvent in which the acetylene stored is dissolved. However, for special applications there exist some acetylene cylinders containing a porous mass and no solvent. For the periodic inspection cycle, due regard should be given to the different types of construction of cylinders and porous masses. The remainder of this document should be read considering these differences. The primary objective of the presence of the porous mass is to limit an acetylene decomposition, should it be initiated, and thus prevent a cylinder incident. If some porous mass is missing, or if a defect (e.g. a cavity, crack or void of significant size) exists as a result of breakdown or subsidence of the porous mass, then the decomposition could progress at a rate which can cause a violent failure of the cylinder. 4

7 1 Scope This European Standard specifies seamless and welded steel or seamless aluminium alloy cylinders intended for the transport of acetylene in cylinders of water capacity up to 150 l and specifies the requirements for the periodic inspection and maintenance of acetylene cylinders, regardless of the method of manufacture of the shell. This European Standard also applies to solvent free acetylene cylinders. This European Standard also specifies a procedure to qualify existing gas cylinders for free movement between member states of the European Union (see annex A). 2 Normative references This European Standard incorporates by dated or undated reference provisions from other publications. These normative references are cited at the appropriate places in the text, and the publications are listed hereafter. For dated references, subsequent amendments to or revisions of any of these publications apply to this European Standard only when incorporated in it by amendment or revision. For undated references the latest edition of the publication referred to applies (including amendments). EN 1800:1998, Transportable gas cylinders Acetylene cylinders Basic requirements and definitions. EN , Transportable gas cylinders Gas cylinder identification (excluding LPG) Part 1: Stampmarking. EN , Transportable gas cylinders Gas cylinder identification (excluding LPG) Part 2: Precautionary labels. EN , Transportable gas cylinders Cylinder identification Part 3: Colour coding system. EN ISO 13341, Transportable gas cylinders Fitting of valves to gas cylinders (ISO 13341:1997). 3 Terms and definitions For the purposes of this European Standard, the following terms and definitions apply. 3.1 cylinder shell pressure vessel manufactured for storage and transport and suitable for containing a porous mass, a solvent, where relevant, and acetylene 3.2 complete cylinder cylinder shell ready to be charged with acetylene gas, which is complete with porous mass, solvent where relevant, saturation gas, valve, and any valve protection permanently fixed to the cylinder shell 3.3 porous mass single or multi-component substance introduced into, or formed in the cylinder shell, in order to fill it and due to its porosity allow the absorption of the solvent and acetylene gas. The porous mass can be of two types a) a non-monolithic porous substance consisting of granular, fibrous or similar substances without the addition of any binding materials; 5

8 b) a monolithic porous substance consisting of materials having reacted to form a compact product or of materials connected together through a binding compound(s). This type of porous substance may be manufactured with a controlled clearance between the shell and the substance (see annex D) 3.4 porosity ratio expressed in percentage of the volume of the solvent, which can be filled in the cylinder equipped with the porous mass, to the water capacity of this cylinder without porous mass (determined according to annex B of EN 1800:1998) 3.5 solvent liquid which is absorbed by the porous mass and is capable of dissolving and releasing the acetylene gas 3.6 saturation gas mass of acetylene dissolved in the solvent in the cylinder at atmospheric pressure and 15 C 3.7 tare weight for acetylene cylinders the tare weight is expressed by indicating weights corresponding to: tare A sum of the empty weight of the cylinder shell, the porous mass, the specified mass of solvent, the valve and the mass of all other parts which are permanently attached (e.g. by clamping or bolting) to the cylinder when it is going to be filled TARE A plus the weight of acetylene required to saturate the solvent at atmospheric pressure and at a tare S temperature of 15 C tare F for solvent free acetylene cylinders the tare weight is expressed by indicating a TARE F, where TARE F of an acetylene cylinder is TARE A minus the weight of solvent 4 General 4.1 Requirements for inspection The periodic inspection of acetylene cylinders shall be carried out only by competent and trained persons who shall ensure that the cylinders are fit for continued safe use. NOTE A competent person is a person who has the necessary technical knowledge, experience and authority to assess and approve materials for use with gases and to define any special conditions of use that are necessary. Such a person will also normally be formally qualified in an appropriate technical discipline. Due to the presence of a porous mass in the cylinder neither a pressure test (hydraulic or pneumatic) nor a visual inspection of the internal surface of the shell, is required by this standard. Where cylinders are manufactured according to National Regulations and are intended to be qualified under the Transportable Pressure Equipment Directive (TPED) for free movement and use between member states of the European Union, additional requirements are specified in annex A. 6

9 4.2 Intervals between periodic inspections A cylinder shall fall due for a periodic inspection on its first receipt by a filler after the expiry of the interval of 5 years in the case of non-monolithic massed cylinders, or 10 years in the case of monolithic massed cylinders. NOTE These intervals conform to the current RID/ADR regulations. However additional initial inspection requirements for newly massed cylinders are required as follows: a) Non-monolithic mass For all newly massed cylinders an initial inspection according to this standard shall be either before 2 years in service or before the first fill after the 2 years have elapsed. b) Monolithic masses For all newly massed cylinders an initial inspection according to this standard shall be either before 3 years in service or before the first fill after the 3 years have elapsed. After the initial inspection according to either a) or b), the normal period as stated above shall apply. Provided the cylinder has been subjected to normal conditions of use and has not been subjected to abusive or abnormal conditions rendering the cylinder unsafe, there is no general requirement for the user to return a gas cylinder before the content has been used, even though the test interval may have lapsed. 5 Preparation of gas cylinder 5.1 Removal of gas Before proceeding with the inspection, cylinders shall be depressurised of gas. Cylinders shall be checked for pressure both before and after depressurisation. Depressurization shall be carried out in a safe manner having due regard to the characteristics of acetylene. Depressurisation shall be carried out over a period long enough to ensure a removal of all acetylene, except saturation gas (see clause 3.6). Precautions shall be taken because variations in temperature influence the quantity of acetylene in the form of saturation gas. NOTE The absence of a positive pressure reading does not clearly indicate the absence of excess gas due to the possibility of a blocked valve (see annex B). In case of any doubts regarding the efficiency of the depressurisation cycle, the cylinder shall be weighed. A cylinder weighing greater than the tare weight (see 3.7) stamped on the cylinder is not always a clear indication of the presence of excess gas. Consideration should be given to the possibility of contamination, such as an excess of solvent or the ingress of water. A cylinder weighing less than or equal to the stamped tare weight is not always a clear indication of the absence of gas under pressure. Consideration should be given to factors such as a possible solvent shortage or external corrosion causing a loss of shell weight. 5.2 Preparation for external visual inspection Each cylinder shall be cleaned and have all loose coatings, corrosion products, tar, oil or other foreign matter removed from its external surface by a suitable method, e. g. by brushing, shot blasting (under closely controlled conditions to ensure that there is no leakage of acetylene into the brushing or shot blasting cabinet) water jet abrasive cleaning, chemical cleaning or other methods. Care shall be taken at all times to avoid damaging the cylinder and pressure relief devices where fitted. NOTE The external visual inspection, in accordance with 6.1, can be carried out at this stage 7

10 5.3 Valve removal Before removing the valve from an acetylene cylinder it shall be determined that the cylinder has been completely depressurised as described in 5.1. If there is any reason to believe that a valve is blocked (e.g. the lack of an audible release of gas when opening the valve) and that the cylinder may still contain residual gas under pressure, checks shall be made e.g. by introducing an inert gas at a pressure lower than 5 bar and observing its discharge. If it is found that the valve is obstructed, then a suitable method shall be employed to remove the gas or the valve, taking into consideration the design of the valve and ensuring that all necessary precautions are taken having due regard to the hazards that can result from an uncontrolled operation (see annex B). Devalving shall take place in the open or in a ventilated area. The temperature of the cylinder when removing the valve should be close to the ambient temperature within the inspection area, so as to avoid either excess venting of residual gas or ingress of air. NOTE The cylinders should not be left open or without valves longer than necessary for the inspection. 5.4 Removal of neck/core hole filters Acetylene cylinders usually contain neck filters/core hole packing, consisting of filter (or metallic gauze) and felts. Neck filters and packing materials, placed between the top of the porous mass and the base of the valve stem, shall be removed, as appropriate, to enable an inspection of the porous mass in accordance with the inspection requirements of the porous mass manufacturer or the inspection body. Some porous mass manufacturers equip monolithic mass acetylene cylinders with a wooden plug, which forms an integral part of the porous mass. This plug, which is situated below the neck filter (or metallic gauze), shall be left intact and not removed for the purpose of the visual examination, provided that the wooden plug is in the right position, permitting the measurement of the gap in accordance with the manufacturer's instructions. If on a previous inspection the wooden plug has been tampered with or removed by mistake or is not in the right position this plug shall be replaced with a new one in line with the porous mass manufacturer's approval/specification. Special care shall always be taken when removing filters or packing material in view of the possibility of some restrictions at the neck with residual pressure underneath, which, if suddenly released, can blow the filter out with some of the porous substance and can cause injury. NOTE The presence of fine carbon powder or other contaminants on the filters or packing material is indicative of a flashback having occurred. 6 Inspection and maintenance 6.1 Inspection procedure The external surface of each cylinder shall be inspected for: a) dents, cuts, gouges, bulges, cracks, laminations (as defined in Table C.1) or excessive base wear; b) heat damage, torch or electric arc burns (as defined in Table C.1); c) corrosion (as defined in Table C.2); d) other defects such as illegible or unauthorised stamp markings, unauthorised additions or modifications (see Table C.1); e) integrity of all permanent attachments. Damaged valve guards, threaded neck rings and foot rings may be repaired or replaced as appropriate. No welding or any heat shall be directly applied to the pressure containing part of the cylinder. If welding is 8

11 performed on a non-pressure-containing part of the cylinder, due care shall be taken with regard to the presence of acetylene and solvent. For rejection criteria, see annex C. Cylinders no longer suitable for future service shall be rendered unserviceable (as defined in clause 10). 6.2 Examination of the porous mass General Following 5.4, the porous mass shall be examined for the presence of visible contamination or other defects which could affect the suppression of an acetylene decomposition. The examination shall be performed, where necessary, by the appropriate use of special spark-resistant tools such as metal wire probes, rods, feeler or clearance gauges (see annex D) to check the firmness and the presence of voids or other defects in the mass to give the rejection criteria. Care shall be taken to ensure that the porous mass is not damaged by the inspection tools Contamination The porous mass shall be checked visually for contamination such as the presence of significant fine carbon powder and water, or oil deposits or if there has been a discolouration of the porous mass. Depending on the level of such contamination, the competent person shall decide if the porous mass is to be rejected Monolithic masses - Cracking, crumbling or cavitation The visual inspection shall verify that the porous mass shows: a) no excessive top clearance (gap between the top of the cylinder and the monolithic porous mass); The maximum gap between the top of the cylinder and the monolithic porous mass shall not exceed that in the type approval, if specified, for that cylinder. Those gaps up to the maximum used in the type approval tests shall apply. If at a later stage, cylinders with other gap sizes pass the requirements of the backfire test as in EN 1800, and are approved, then these gap sizes may also apply. If top clearance specification or guidance is not available for a given cylinder, the gap size shall not exceed 2 mm for an asbestos free porous mass and 5 mm for all other monolithic masses. b) no excessive cracking; Only small cracks without visible flanks are acceptable for all masses, provided that they do not incorporate break outs and do not allow the mass to dislodge. This can be checked by applying a gentle lateral load with a gloved finger. Porous masses with cracks with visible flanks are not acceptable and shall be rejected (for examples see Annex F). c) no excessive crumbling; Crumbling of the porous mass is acceptable if it is arising from the collar of the porous mass only and if it is so little that the maximum allowed gap is not exceeded at any point. Small break outs in the top of the cylinder neck/shoulder area are acceptable and may be repaired by a method validated and approved by the mass manufacturer, e.g. by backfire test. Cylinders with masses that show crumbling in excess of the allowable shall be rejected. d) no void or cavities. The porous mass shall be checked to ensure that there are no voids or cavities between the porous mass and the cylinder wall by verifying there is no lateral movement. A cylinder that demonstrates lateral movement of porous mass shall be rejected. If the cylinder is equipped with a wooden plug (see 5.4) it shall be checked, by applying a gentle load to ensure that the plug is firmly fixed in its position and there is no lateral movement of the wooden plug. There may be a tolerance of 1 mm between the porous mass and the wooden plug. 9

12 6.2.4 Non-monolithic masses Compaction Non-monolithic porous masses which have been subjected to compaction, or exhibit a loss of compaction shall be rejected, or repaired in accordance with Pressure relief devices including fusible plugs Where fusible plugs or other pressure relief devices are used they shall be examined for damage. Where damage is found the device shall be replaced and checked for gas tightness. If it is decided to replace relief devices with solid plugs, this shall be performed in accordance with a written procedure, approved by the inspection body. 6.4 Inspection of valves Before being refitted to a cylinder, the valve shall be cleaned and inspected. Any damaged or defective parts shall be replaced (see annex E). Attention shall be paid to the condition of threads, and gauges shall be used as appropriate. 6.5 Inspection of cylinder threads The internal neck threads of the cylinder and other threaded openings shall be examined to ensure that they are of full form and clean. They shall be checked for burrs, cracks and other imperfections. Where necessary, and where the design permits, damaged threads may be rectified by a suitable method and shall be checked with the appropriate gauge. 6.6 Repair of non-monolithic porous mass A non-monolithic mass that has been rejected due to compaction shall only be repaired if the repair does not impair the safety of the cylinder in operation. The repair of a non-monolithic mass shall be performed according to the instructions of the porous mass manufacturer or, if these cannot be obtained, to instructions of the competent person and the method to be used shall be verified by testing in accordance with EN The quantity of material added shall be recorded, the tare weight of the cylinder adjusted as appropriate, and the stamp marking adjusted accordingly. A cylinder, which contains a rejected porous mass which is not suitable for repair in accordance with this clause, shall be rendered unserviceable or may be considered for use with the porous mass replaced according to Replacement of porous mass If the porous mass is no longer acceptable but the external condition of the cylinder shell is satisfactory, then either the existing porous mass shall be replaced, and the cylinder shell reused, or the complete cylinder shall be made unserviceable. The removal of the existing porous mass and the solvent shall be carried out in a safe manner and the cylinder thoroughly cleaned and inspected. Care shall be taken if the porous mass contains asbestos. The internal surface of the cylinder shall be examined for corrosion or other visible defects and if the cylinder shell is found to be satisfactory, it is permissible to introduce a new porous mass. Each cylinder shall be hydraulically tested at the stamped test pressure by a competent person prior to reintroducing the new approved porous mass. 10

13 If a different porous mass is employed the original porous mass manufacturer's identification mark shall be removed and the identity of the new porous mass, manufacturer and all other characteristics necessary to ensure safe operation, as defined on the approval certificate, shall be stamped onto the cylinder. In addition the new tare weight shall be stamped onto the cylinder having obliterated the old tare weight marking. 6.8 Reassembling Cylinders meeting the requirements of this standard shall be reassembled by replacing, as specified by the porous mass manufacturer, any packing materials in the neck end and fitting new filters in such a way as to ensure that when the valve is fitted contact is made between the base of the valve stem and the filters/packings. New or reconditioned valves shall be fitted to the cylinder using a suitable jointing material and the torque necessary to ensure a seal between the valve and the cylinder, in accordance with EN ISO If required, a test date ring indicating the next test date may be fitted over the stem of the valve, prior to the valve being fitted. 7 Identification of content The cylinder content shall be identified as being acetylene in accordance with EN and EN Markings Each cylinder which passes the cylinder shell and porous mass inspection shall be marked with the date of the inspection and the symbol of the inspection body or test station, in accordance with EN Where an alteration of the tare weight is necessary as a consequence of replacement of a footring, neck ring, guard, valve or addition of porous mass material (see 6.6), the old tare marking(s) shall be obliterated (or crossed out) and the new tare weight(s) and total weight stamped. The next test date shall be shown by an appropriate method such as a disc fitted between the valve and the cylinder indicating the date (year) of the next periodic inspection. 9 Records An inspection record shall be retained for not less than the period between two consecutive inspections on the same cylinder. It shall record sufficient information to positively identify the cylinder and the results of the inspection. The following information shall be available: - owner's name; - manufacturer's or owner's serial number; - type and weight of porous mass added, if any; - attachment replacement, if any; - cylinder tare weight change if appropriate; 11

14 - result of test (pass or fail); - present test date; - Identification symbol of inspection body or test station; - Identification of inspector. 10 Disposal of unserviceable cylinders Methods used for disposing of non-acetylene cylinders are inappropriate for acetylene cylinders, on account of the nature of the contents of an acetylene cylinder. When disposing of acetylene cylinders very careful consideration shall be given to the fact that the cylinders contain residual acetylene, solvent (DMF or acetone) and porous mass (which can contain asbestos). 12

15 Annex A (informative) Acetylene cylinders manufactured according to National Regulations A.1 Scope This annex specifies those checks, inspections and tests which should be performed in order to qualify existing acetylene cylinders, manufactured according to National Regulations, to ensure their conformance to the TPED for free movement and use between all Member States of the European Union. The annex does not apply to acetylene cylinders manufactured according to EU Directives 84/525/EEC, 84/526/EEC or 84/527/EEC, or to European Standards for gas cylinder construction. A.2 Definitions and symbols : Official stampmark required by the TPED to certify existing gas cylinders conforming to RID/ADR for use throughout the European Union. A.3 General recommendations A.3.1 The owner of the gas cylinders should indicate to the inspection body the types and the number of gas cylinders presented for qualification. For each of the cylinders the following information should be made available for documentation and subsequent calculation: - manufacturer; - serial number; - date of manufacture (cylinder shell and porous mass; - regulation or specification to which the cylinder was manufactured; - working pressure; - test pressure; - external diameter; - minimum wall thickness; - minimum yield stress; 13

16 - water capacity; - type of porous mass; - type of solvent; - maximum acetylene charge; - tare (A or S or F). The inspection body should verify that this list contains all the necessary information to clearly define the cylinder shell and porous mass (see example of production testing certificate for the shell in the relevant annex of e.g. EN , pren and EN 1975 and for the porous mass in EN 1800, for the above listed parameters only). A.3.2 The inspection body should verify that these cylinders are not on any relevant national safety related recall list. Additionally if any restrictions of use apply they should be maintained for further use. A.3.3 The inspection body should verify that the wall thickness of the gas cylinders is equal to, or greater than, the minimum wall thickness, as calculated in accordance with EN , pren or EN 1975, for the corresponding yield stress of the cylinder. A.3.4 The inspection body should verify that the manufacturing certificates or equivalent records of the cylinder shells are available. When manufacturing certificates are not available, the inspection body should verify that all relevant type testing and manufacturing batch testing have been performed. It should also verify that the porous mass has been approved to a procedure equivalent to EN 1800, or to ISO or ISO A.3.5 The periodic inspection according to this standard should all be performed during the course of the requalification. A.4 Special markings A gas cylinder passing the periodic inspection may only be stamped with the mark provided that the requirements under A.3 have been fully verified. A.5 Inspection report The inspection body shall prepare a report for each type of cylinder. All relevant certifications, new tests and inspections performed should be attached to this report. 14

17 Annex B (informative) Procedure to be adopted when a cylinder valve is suspected to be obstructed B.1 If there is any doubt when the valve of a gas cylinder is opened that gas is not being released and the cylinder can still contain gas under pressure, a check should be made to establish that the free passage through the valve is not obstructed. The method adopted should be a recognized procedure such as one of the following or one that provides equivalent safeguards: a) First check to establish that the total weight of the cylinder is the same as the tare stamped on the cylinder, adjusted if necessary to represent the condition of the cylinder being weighed (e.g. Tare A is likely to require adjustment in most cases). If there is a positive difference, the cylinder can contain either liquefied gas under pressure or contaminants. b) Introduce inert gas at a pressure of up to 5 bar and checking its discharge. c) Use the device shown in Figure B.1 to pump air into the cylinder by hand. B.2 When it is established that there is no obstruction to gas flow in the cylinder valve, the valve may be removed. B.3 When a cylinder is found to have an obstructed gas passage in the valve, the cylinder should be set aside for special attention as follows: Unscrew partially the valve within a glanded cap, secured and jointed to the cylinder and vented to a safe discharge. The principles of a suitable device are illustrated in Figure B.2. This procedure should be carried out only by trained personnel. When the gas, if any, has been released and the pressure within the cylinder reduced to atmospheric, the valve may be removed. 15

18 All dimensions in millimetres Key 1 Rubber tube 8 internal diameter 13 outside diameter ground to olive shape and bonded 2 Steel tube 3 internal diameter 8 outside diameter 3 Bond 4 Rubber bulb (volume approximately 30 cm 3 ) 5 Hand pressure Figure B.1 Device for detecting obstructed cylinder valve 16

19 Key 1 Rubber gland packing 2 Extractor casing 3 Control valve 4 Joint ring 5 Clamp Figure B.1 Typical device used for the removal of a damaged gas container valve 17

20 Annex C (normative) Description, evaluation of defects and conditions for rejection of acetylene gas cylinders at time of visual inspection C.1 General Gas cylinder defects may be physical or material or due to corrosion as a result of environmental or service conditions to which the cylinder has been subjected during its life. The object of this annex is to give general guidelines to the gas cylinder users as to the application of rejection criteria. Any defect in the form of a sharp notch may be removed by grinding, machining or other approved methods. Due to the possibility of spark generation care should be taken on account of the presence of solvent and acetylene. After such a repair, checking of the wall thickness, e.g. ultrasonically, should be repeated. C.2 Physical or material defects Evaluation of physical or material defects should be in accordance with Table C.1. C.3 Corrosion C.3.1 General The cylinders can be subjected to environmental conditions that could cause external corrosion of the metal. There is difficulty in presenting definite rejection limits in tabular form for all sizes and types of cylinder and their service conditions. The limits of rejection have been established following considerable field experience. Extensive experience and judgement are required in evaluating whether cylinders that have corroded internally are safe and suitable at the time of remassing for return to service. It is important that the surface of the metal is cleaned of corrosion products prior to the inspection of the cylinder. C.3.2 Types of corrosion The types of corrosion generally may be classified as in Table C.2. 18

21 Table C.1 Rejection limits relating to physical and material defects in the cylinder shell Defect Definition Rejection limits in accordance with clause 6 a Repair or render unserviceable Bulge Visible swelling of the cylinder All cylinders with such a defect Render unserviceable Dent A depression in the container that has neither penetrated nor removal metal and is greater in depth than 1 % of the outside diameter When the depth exceeds 3 % of the external diameter of the cylinder, or when the diameter of the dent is less than 15 times its depth Render unserviceable Cut or gouge (see Figure C.1) A sharp impression where metal has been removed or redistributed and For seamless steel and welded steel: For seamless aluminium: whose depth exceeds 5 % of the cylinder wall thickness When the depth of the cut or gouge exceeds10 % of the wall thickness; or When the depth of the cut or gouge exceeds 15 % of the wall thickness; or Repair possible c When the length exceeds 25 % of the external diameter of the cylinder When the length exceeds 25 % of the external diameter of the cylinder Render unserviceable Crack (see Figure C.2) A split or rift in the metal All cylinders with such defects Render unserviceable Fire damage (see Figure C.3) Excessive or localized heating of a cylinder usually indicated by: a) partial melting of the cylinder All cylinders in categories a) and b) Render unserviceable b) distortion of cylinder c) charring or burning of paint d) fire damage to valve melting of plastic guard or date ring All cylinders in categories c) and d) may be acceptable after inspection Repair if possible Plug or neck inserts Additional inserts fitted in the cylinder neck, base or wall (for old cylinders only) All cylinders unless it can be clearly established that addition is part of approved design Repair possible Stamping Marking by means of a metal punch All cylinders with illegible, modified or incorrect or incorrectly modified markings Render unserviceable b Arc or torch burns (see Figure C.4) Partial melting of the container, the addition of weld metal or the removal of metal by scarfing or cratering All cylinders with such defects Render unservicable Suspicious marks Introduced other than by the cylinder manufacturing process and approved repair All cylinder with such defects Continued use additional inspection a When applying the rejection criteria given in Table C.1, the conditions of use of the cylinders, the severity of the defect and the safety factors in the design shall be taken into consideration. b If it can be clearly established that the cylinder fully complies with the appropriate specifications, an altered marking may be acceptable and inadequate markings may be corrected. c Provided that after repair by suitable metal removal technique, the remaining wall thickness is at least equal to the design minimum wall thickness. 19

22 Types of corrosion General corrosion (see Figure C.5) Local corrosion Chain, pitting or line corrosion (see Figure C.6) Crevice corrosion a Table C.2 Rejection criteria for corrosion of the cylinder wall Definition Loss of wall thickness over an area of more than 20 % of the total surface area of the cylinder Loss of wall thickness over an area of less than 20 % of the total surface area of the cylinder, except for the other types of local corrosion described below Corrosion forming a narrow longitudinal or circumferential line or strip, or isolated craters or pits (see Figure C.7) which are almost connected Corrosion associated with and taking place or immediately around, an aperture Rejection limits in accordance with clause 6 a If the original surface of the metal is no longer recognizable; or If the depth of penetration exceeds 10 % of the original thickness of wall b ; or If the wall thickness is less than design minimum wall thickness If the depth of penetration exceeds 20 % of the original thickness of the cylinder wall b or if the wall thickness is less than design thickness If the total length of corrosion in any direction exceeds the diameter of the cylinder and the depth exceeds 10 % of the original wall thickness b If, after thorough cleaning, the depth of penetration exceeds 20 % of the original wall thickness Repair or render unserviceable Repair if possible Repair if possible (repeat requirements of clause 6) Render unserviceable Repair if possible (repeat requirements of clause 6) Repair if possible c Repair if possible c If the bottom of the defect cannot be seen and if its extent cannot be determined using appropriate equipment, the cylinder shall be scrapped. b If corrosion has reached limits of depth or extent, the remaining wall thickness should be checked with an ultrasonic device. The wall thickness may be less than the minimum, under certain conditions. When applying the rejection criteria given in this table, the conditions of use of the cylinders, the severtiy of the defect and safety factors in the design should be taken into consideration. c Provided that after the repair by a suitable metal removal technique, the remaining wall thickness is at least equal to the design minimum wall thickness. 20

23 Figure C.1 Cut or gouge Figure C.2 Crack Figure C.3 Fire damage Figure C.4 Arc or torch burns Figure C.5 General corrosion Figure C.6 Line corrosion Figure C.7 Isolated pits 21

24 Annex D (informative) Tools and clearance gauges and diagrammatic illustration of the top of (monolithic and non-monolithic) acetylene cylinders 1 2 H h Key 1 Example of inspection gauge for porous mass 2 Disintegrated porous mass 3 Undamaged porous mass 3 h H Void Depth of disintegrated mass Figure D1 Inspection and clearance gauges for non-monolithic porous mass 22

25 Figure D.2 Example of top clearance gauges for different gap sizes of cylinders with a monolithic porous mass 23

26 Annex E (informative) Inspection and maintenance of valves and their connections Check all threads to ensure the thread diameters, form, length, and taper are satisfactory. If threads show signs of distortion, deformation, or burring, rectify these faults. Excessive thread damage or serious deformation of the valve body, handwheel, spindle or other components is cause for replacement. Maintenance of the valve includes general cleaning together with replacement of elastomers and worn or damaged components, packing and safety devices, where necessary. Where the use of lubricants/elastomers is permitted, ensure that they are compatible with both the solvent and acetylene, in accordance with EN ISO After the valve has been re-assembled check for leakage and correct operation. This may be done prior to the valve being refitted to the cylinder, or during and after the first gas charge subsequent to the inspection of the cylinder. NOTE More detailed information on valve maintenance will be included in the following standard, currently in preparation: pren 14189:2001, Transportable gas cylinders Inspection and maintenance of cylinder valves at time of periodic inspection of gas cylinders. 24

27 Annex F (normative) Cracks on porous masses a) Hairline crack without visible flanks: b) Crack with visible flunks: The cylinder may be further used provided there are no break outs and the porous mass cannot be dislodged. The cylinder shall be rejected. Figure F.1 Cracks on porous mass 25

28 Bibliography EN , Transportable gas cylinders Specification for the design and construction of refillable transportable seamless steel gas cylinders of water capacities from 0,5 litre up to and including 150 litres Part 1: Cylinders made from seamless steel with an R m value of less than Mpa. EN 1975, Transportable gas cylinders Specification for the design and construction of refillable transportable seamless aluminium and aluminium alloy gas cylinders of capacity from 0,5 litre up to 150 litre. pren , Transportable gas cylinders Refillable welded steel gas cylinders Design and construction Part 1: Welded steel. EN ISO :1997, Transportable gas cylinders Compatibility of cylinder and valve materials with gas contents Part 1: Metallic materials (ISO :1997). EN ISO , Transportable gas cylinders Compatibility of cylinder and valve materials with gas contents Part 2: Non-metallic materials (ISO :2000). ISO :2000, Cylinders for acetylene Basic requirements Part 1: Cylinders without fusible plugs. ISO :2000, Cylinders for acetylene Basic requirements Part 2: Cylinders with fusible plugs. Council Directive 1999/36/EC of 29 April 1999 on transportable pressure equipment (TPED) 84/525/EEC Council Directive of 17 September 1984 on the approximation of the laws of the Member States relating to seamless, steel gas cylinders 84/526/EEC Council Directive of 17 September 1984 on the approximation of the laws of the Member States relating to seamless, unalloyed aluminium and aluminium alloy gas cylinders 84/527/EEC Council Directive of 17 September 1984 on the approximation of the laws of the Member States relating to welded unalloyed steel gas cylinders ADR RID European agreement on the International Carriage of Dangerous Goods by Road Regulations concerning the International Carriage of Dangerous Goods by Rail 26

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