en 1440 2008+a1 2012

EUROPEAN STANDARD

NORME EUROPÉENNE

EUROPÄISCHE NORM

EN 1440:2008+A1

March 2012

ICS 23.020.30 Supersedes EN 1440:2008

English Version

LPG equipment and accessories - Periodic inspection of transportable refillable LPG cylinders

Equipement et accessoires GPL - Contrôle périodique des bouteilles de GPL transportables et réutilisables

Flüssiggas-Geräte und Ausrüstungsteile - Wiederkehrende Prüfung von ortsbeweglichen, wiederbefüllbaren Flaschen

für Flüssiggas (LPG)

This European Standard was approved by CEN on 6 January 2008 and includes Amendment 1 approved by CEN on 30 January 2012. 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 CEN-CENELEC 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 CEN-CENELEC Management Centre has the same status as the official versions. CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United Kingdom.

EUROPEAN COMMITTEE FOR STANDARDIZATION C O M I T É E U R O P É E N D E N O R M A LI S A T I O N EUR OP ÄIS C HES KOM ITEE FÜR NOR M UNG

Management Centre: Avenue Marnix 17, B-1000 Brussels

© 2012 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members.

Ref. No. EN 1440:2008+A1:2012: E

Licenced by LIBNOR to LIBNOR Technical Committee NL TC 58 NL TC Members Use Only / Date: 22/05/2014 Single-user only. Copying and Networking Prohibited

EN 1440:2008+A1:2012 (E)

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Contents Page

Foreword ..............................................................................................................................................................4

Introduction .........................................................................................................................................................5

1 Scope ......................................................................................................................................................6

2 Normative references ............................................................................................................................6

3 Terms and definitions ...........................................................................................................................7

4 Written scheme of inspection ...............................................................................................................8

5 Procedures for periodic inspection .....................................................................................................85.1 General ....................................................................................................................................................85.2 !Protected cylinders"""" .................................................................................................................. 11

6 !Inspections and tests"""" .............................................................................................................. 116.1 External visual inspection ................................................................................................................. 116.1.1 Preparation for external visual inspection ................................................................................... 116.1.2 Inspection procedure ....................................................................................................................... 116.1.3 Rejection criteria ............................................................................................................................... 126.2 Proof pressure test ............................................................................................................................. 126.2.1 General ................................................................................................................................................ 126.2.2 Hydraulic proof pressure test ......................................................................................................... 126.2.3 Pneumatic proof test and leak test ................................................................................................... 136.3 Check of the internal condition of the cylinder ............................................................................... 146.3.1 Check of the internal condition for welded steel LPG cylinders and LPG cylinders of

alternative design and construction .............................................................................................. 146.3.2 Check of the internal condition of aluminium and composite cylinders ................................ 156.4 Inspection of cylinder threads ........................................................................................................... 156.4.1 General ................................................................................................................................................ 156.4.2 Internal threads .................................................................................................................................. 156.4.3 External threads ................................................................................................................................ 166.4.4 Damaged threads .............................................................................................................................. 166.5 Inspection of valves ........................................................................................................................... 16

7 Final operations .................................................................................................................................. 167.1 Drying ................................................................................................................................................... 167.2 Valving ................................................................................................................................................. 167.3 Tare !!!!mass"""" ................................................................................................................................. 167.4 Marking ................................................................................................................................................ 167.5 Purging ................................................................................................................................................ 16

8 !Repair of LPG welded steel cylinders"""" .................................................................................... 178.1 Major repairs ....................................................................................................................................... 178.2 Minor repairs ....................................................................................................................................... 178.3 Requirements for repair ..................................................................................................................... 17

9 Records ................................................................................................................................................ 17

Annex A (normative) Specific requirements for welded and brazed steel LPG cylinders ....................... 18

Annex B (normative) Specific requirements for welded steel LPG cylinders in accordance with EN 14140:2003+A1 or the equivalent standard ...................................................................................... 20

B.1 General ................................................................................................................................................. 20B.2 Procedure for establishing rejection criteria carbon steel cylinders ............................................ 20B.3 Rejection criteria for stainless steel cylinders ................................................................................ 22


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Annex C (normative) Specific requirements for welded aluminium LPG cylinders .................................. 25

Annex D (normative) Specific requirements for composite LPG cylinders ................................................ 27D.1 Establishment of rejection criteria .................................................................................................... 27D.1.1 General ................................................................................................................................................. 27D.1.2 Procedure ............................................................................................................................................. 27D.2 Examples of rejection criteria ............................................................................................................ 28

Annex E !(informative)" !Requirements for 15-year periodic inspection interval for welded and brazed steel cylinders manufactured before 2015-01-01" .................................................... 34

E.1 General ................................................................................................................................................. 34E.2 Concept of control ............................................................................................................................... 34E.3 Conditions ............................................................................................................................................ 35

Annex F (informative) Guidance on requirements for 10-year periodic inspection interval on composite cylinders ............................................................................................................................ 36

Annex G !(normative)" Periodic inspection procedure for a particular design of protected cylinder ................................................................................................................................................. 37

G.1 Scope and cylinder description ......................................................................................................... 37G.2 Cylinders design and manufacturing requirements ........................................................................ 38G.2.1 Steel cylinder ....................................................................................................................................... 38G.2.2 External protection .............................................................................................................................. 38G.2.3 Marking and recording requirements ................................................................................................ 38G.3 Inspection at filling .............................................................................................................................. 38G.4 Periodic destructive tests on batch sampling .................................................................................. 38G.4.1 Testing procedure ............................................................................................................................... 38G.4.2 Destructive tests .................................................................................................................................. 39G.4.3 Rejection criteria and batch sampling .............................................................................................. 39G.4.4 Periodic inspection tests reports and records ................................................................................. 40

Annex H (normative) !Periodic inspection procedure for cylinder populations not covered by the ADR"""" ........................................................................................................................................... 41

Annex I (informative) !Requirements to be fulfilled to extend period between two periodic inspections to 15 years for RID/ADR welded steel LPG cylinders""""............................................ 42

Annex J (informative) !Alternative test applicable to commercial butane cylinders with less than 6,5 l water capacity"""" ................................................................................................................ 44

Bibliography ...................................................................................................................................................... 45


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Foreword

This document (EN 1440:2008+A1:2012) has been prepared by Technical Committee CEN/TC 286 “Liquefied petroleum gas equipment and accessories”, the secretariat of which is held by NSAI.

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 September 2012, and conflicting national standards shall be withdrawn at the latest by September 2012.

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

This European Standard has been submitted for reference into the RID (Regulations concerning the International Carriage of Dangerous Goods by Rail) and/or in the technical annexes of the ADR (European Agreement concerning the international carriage of Dangerous goods by Road). !deleted text"

The main changes between this version of the !Standard" and the 2005 version is that this version combines EN 1440:2005, EN 14767:2005, EN 14795:2005 and EN 14914:2005 into a single !European Standard".

This document includes Amendment 1, approved by CEN on 2012-01-30.

The start and finish of text introduced or altered by amendment is indicated in the text by tags ! ".

This European Standard supersedes !EN 1440:2008", EN 14767:2005, EN 14795:2005 and EN 14914:2005.

!The changes in this amendment (EN 1440:2008/FprA1:2011) include:

inclusion of the new RID/ADR requirement relative to the 15 year interval between periodic inspections introduced in ADR 2011;

revision of procedures of periodic inspection in order to meet all RID/ADR requirements;

transfer of the requirements for the testing of cylinders with a water capacity less than 6,5 l from the body of the text to new Annex J."

According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United Kingdom.


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Introduction

The primary objective of the periodic inspection of transportable refillable liquefied petroleum gas (LPG) cylinders is that, at the completion of the tests, the cylinders can be re-introduced into service for a further period of time.

The very large populations of traditional steel LPG cylinders in use have led to the development of alternative methods of inspection.

This European Standard has !deleted text" been prepared to reflect the current state of the art for period inspecting of LPG cylinders, and is based on the operating experience of many hundreds of millions of cylinder years of service.

This European Standard calls for the use of substances and procedures that can be injurious to health if adequate precautions are not taken. It refers only to technical suitability and does not absolve the user from legal obligations relating to health and safety at any stage.

It has been assumed in the drafting of this European Standard that the execution of its provisions is entrusted to appropriately qualified and experienced people.

Where judgements are called for, it has been assumed that they are made by competent persons who have been trained specifically for the tasks.

This !European Standard" is a combination of EN 1440:2005, with EN 14767:2005, EN 14795:2005 and EN 14914:2005.


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1 Scope

This European Standard specifies procedures for periodic inspection and testing, for transportable refillable LPG cylinders with a water capacity from 0,5 l up to and including 150 l.

This !European Standard" is applicable to the following:

welded and brazed steel LPG cylinders with a specified minimum wall thickness (see EN 1442 and EN 12807 or the equivalent standard);

welded steel LPG cylinders !manufactured to an alternative design and construction" (see EN 14140:2003+A1 or the equivalent standard);

!NOTE This European Standard also applies to protected cylinders, see 5.3 and Annex G."

welded aluminium LPG cylinders (see EN 13110 or the equivalent standard);

composite LPG cylinders (see EN 14427 or the equivalent standard).

This !European Standard" is intended to be applied to cylinders complying with RID/ADR (including pi marked cylinders) and also to existing non RID/ADR cylinder populations.

This !European Standard" does not apply to cylinders permanently installed in vehicles.

2 Normative references

The following referenced documents are indispensable for the application of this European Standard. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.

EN 837-1, Pressure gauges — Part 1: Bourdon tube pressure gauges — Dimensions, metrology, requirements and testing

EN 837-3, Pressure gauges — Part 3: Diaphragm and capsule pressure gauges — Dimensions, metrology, requirements and testing

!EN 1439:2008", LPG equipment and accessories — Transportable refillable welded and brazed steel Liquefied Petroleum Gas (LPG) cylinders — Procedure for checking before, during and after filling

EN 1442, LPG equipment and accessories — Transportable refillable welded steel cylinders for LPG — Design and construction

EN 10028-7, Flat products made of steels for pressure purposes — Part 7: Stainless steels

EN 12816, Transportable refillable steel and aluminium LPG cylinders — Disposal

!deleted text"

!EN 13322-1, Transportable gas cylinders — Refillable welded steel gas cylinders — Design and construction — Part 1: Carbon steel"

EN 14140:2003+A1:2006, LPG equipment and accessories — Transportable refillable welded steel cylinders for LPG — Alternative design and construction

EN 14427:2004, Transportable refillable fully wrapped composite cylinders for Liquefied Petroleum Gases (LPG) — Design and Construction


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EN 14894, LPG equipment and accessories — Cylinder and drum marking

EN 14912, LPG equipment and accessories — Inspection and maintenance of LPG cylinder valves at time of periodic inspection of cylinders

!EN ISO 4624, Paints and varnishes — Pull-off test for adhesion (ISO 4624)"

EN ISO 4628-3, Paints and varnishes — Evaluation of degradation of coatings — Designation of quantity and size of defects, and of intensity of uniform changes in appearance — Part 3: Assessment of degree of rusting (ISO 4628-3)

EN ISO 14245, Gas cylinders — Specifications and testing of LPG cylinder valves — Self-closing (ISO 14245)

EN ISO 15995, Gas cylinders — Specifications and testing of LPG cylinder valves — Manually operated (ISO 15995)"

ISO 9162, Petroleum products — Fuels (class F) — Liquefied petroleum gases — Specifications

3 Terms and definitions

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

3.1 !inspection body independent inspection and testing body approved by the competent authority"

3.2 competent person !person which by combination of appropriate qualification, training, experience, and resources, is able to make objective judgments on the subject"

3.3 periodic inspection !activities carried out at defined intervals, such as examining, measuring, testing or gauging the characteristics of a pressure vessel and comparing these with specified requirements"

3.4 production batch group of cylinders made consecutively during the same year, by the same manufacturer using the same manufacturing techniques to the same design, nominal size and material specifications on the same production machinery and subject to the same heat treatment conditions

NOTE In this context, "consecutively," need not imply continuous production.

3.5 protected cylinder !cylinder fully covered with a protection against impact and external corrosion so that the cylinder wall cannot be seen"

3.6 casing permanently attached sleeve covering part of, or the whole of the pressure containing envelope of a composite cylinder, usually incorporating a foot ring and a shroud

NOTE Permanently attached means that casing cannot be removed during service without destruction, or by using special tools.


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3.7 !liquefied petroleum gas LPG low pressure gas composed of one or more light hydrocarbons which are assigned to UN 1011, UN 1075, UN 1965, UN 1969 or UN 1978 only and which consists mainly of propane, propene, butane, butane isomers, butene with traces of other hydrocarbon gases"

3.8 tare mass sum of the mass of the empty cylinder, the mass of the valve including a dip tube where fitted, and the mass of all other parts that are permanently attached to the cylinder when it is being filled, e.g. fixed valve guard

!3.9 competent authority authority designated as such in each country in accordance with national regulation"

4 Written scheme of inspection

The interval between periodic inspections shall be dependent on the content of a written scheme.

NOTE A written scheme, describes work procedures, criteria, responsibilities and other minimum requirements.

The !maximum" interval between periodic inspections for welded steel, brazed steel and welded aluminium LPG cylinders shall be 10 years.

!However for welded and brazed steel LPG cylinders manufactured before the date 2015-01-01, this maximum interval can be extended to 15 years, provided the conditions of Annex E are fully met and approval from the relevant competent authority(ies) has been given.

The interval between periodic inspections of RID/ADR welded steel LPG cylinders can be extended to 15 years provided the requirements of Annex I are fulfilled and approval from the relevant competent authority has been given."

For protected cylinders the interval is determined in accordance with G.4.1.

For composite cylinders, the determination of the interval between periodic inspections shall depend on the content of a written scheme that shall be approved by a competent authority.

Annex F gives guidance on conditions to obtain approval for 10-year interval. !deleted text"

5 Procedures for periodic inspection

5.1 General

!Periodic inspections/tests shall be carried out by a competent person under the control of an inspection body based on a written scheme and in accordance with the procedures specified in Table 1.

For composite cylinders the written scheme shall be approved by the competent authority.

NOTE 1 A written scheme describes work procedures, criteria, responsibilities and other minimum requirements.

Cylinders rejected shall be segregated and be either reconditioned, re-tested or rendered unserviceable.

The decision to render a cylinder unserviceable can be taken at any stage during the periodic inspection procedure. With agreement by the owner, a cylinder shall be rendered unserviceable in accordance with EN 12816 so that it cannot be re-issued into service as a pressure vessel.


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NOTE 2 In some countries, render unserviceable, means scrapping.

NOTE 3 With the agreement of the competent authority, the proof pressure test of cylinders can be replaced by an equivalent method based on acoustic emission testing, ultrasonic examination or a combination of acoustic emission testing and ultrasonic examination. EN ISO 16148 may be used as a guide for acoustic emission testing procedures.

NOTE 4 Tests can be performed in any order as determined by the written scheme.

Table 1 – Procedures for periodic inspection

Cylinder types Maximum periodic inspection interval

Procedures

Brazed steel cylinders 10 years External visual inspection as described in 6.1.2.1, 6.1.3 and Annex A

Proof pressure test (hydraulic proof pressure test or, with the agreement of the competent authority, a pneumatic proof test and leak test) as described in 5.2 and 6.2

Internal condition check as described in 6.3.1 and Annex A

Inspection of threads as described in 5.2 and 6.4

Inspection of valves as described in 6.5

Welded steel cylinders in conformity with EN 1442, EN 13322-1 or Council Directive 84/527/EEC Annex I parts 1 to 3

10 years; or

15 years under the conditions of Annex I

Welded and brazed steel cylinders – manufactured before 1st January 2015

10 years; or

15 years under the conditions of Annex E

Welded steel cylinders in conformity with EN 14140 or equivalent standard

10 years

External visual inspection as described in 6.1.2.1, 6.1.3 and Annex B


Internal condition check as described in 6.3.1 and Annex B



Welded steel cylinders in conformity with EN 14140 or equivalent standard – manufactured before 1st January 2015

10 years; or

15 years with the agreement of the competent authority and under the conditions of Annex E


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Table 1 (continued)

Welded aluminium cylinders

10 years External visual inspection as described in 6.1.2.1, 6.1.3 and Annex C

Proof pressure tests (hydraulic proof pressure test or, with the agreement of the competent authority, a pneumatic proof test and leak test) as described in 5.2 and 6.2

Internal condition check as described in 6.3.2



Composite cylinders As determined by the competent authority.

Guidance for 10 year periodic inspection interval described in Annex F

External visual inspection as described in 6.1.2.2, 6.1.3 and Annex D


Internal condition check as described in 6.3.2



Protected cylinders As determined by the competent authority.

Annex G provides guidance for a inspection scheme with an interval of maximum 3 years after putting in service and thereafter every “n” years dependent from the results of the first periodic inspection

As specified in Annex G

Cylinders with a water capacity of less than 6.5 litres

10 years As for welded steel cylinders in conformity with EN 1442 (see above), or, with the agreement of the competent authority, as specified in Annex J

Non ADR/RID welded and brazed steel cylinders

As determined by the competent authority.

15 years under the conditions of Annex E

As specified in Annex H

"


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5.2 !Protected cylinders

An alternative procedure for periodic inspection of protected cylinders is described in Annex G."

!deleted text"

6 !Inspections and tests

6.1 External visual inspection

6.1.1 Preparation for external visual inspection

a) If required, the cylinder shall be cleaned and have all loose coatings or labels, corrosion products, tar, oil or other foreign matter removed from its external surface.

b) Care shall be taken to avoid damaging the cylinder.

c) When cylinders are treated by a process that might remove cylinder material, the inspection body shall decide whether a thickness test is required, e.g. ultrasonic thickness check.

NOTE Cleaning methods can be wire brushing, shot blasting (in accordance with EN ISO 8504 all parts and EN ISO 8501-1), water jet cleaning, chemical cleaning or other suitable methods.

6.1.2 Inspection procedure

6.1.2.1 Welded steel, brazed steel and welded aluminium LPG cylinders, shall be inspected for:

a) dents, cuts, gouges, bulges, cracks, laminations or punctures, applying the criteria for rejection in Annex A, Annex B and Annex C as appropriate;

b) corrosion, giving special attention to areas where water can be trapped, at the base of the cylinder, the junction between the cylindrical shell and the foot-ring, the cylindrical shell and the valve guard or shroud, and in particular hidden corrosion (e.g. data plate) applying the criteria for rejection given in Annex A, Annex B and Annex C as appropriate;

c) other defects (e.g. depressed bung or fire damage) applying the criteria for rejection given in Annex A, Annex B and Annex C as appropriate;

d) integrity of all permanent attachments;

e) integrity of all mandatory permanent markings.

6.1.2.2 Composite cylinders shall be inspected for:

a) cuts, gouges, bulges, cracks or de-laminations, applying the criteria for acceptance/rejection in Annex D;

b) other defects e.g. depressed bung or fire damage applying to the criteria for acceptance/rejection in Annex D;

c) integrity of all permanent attachments;

d) integrity of the mandatory permanent marking.


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6.1.3 Rejection criteria

Defects and rejection limits are described in:

Annex A for specific requirements for welded and brazed steel LPG cylinders;

Annex B for specific requirements for welded steel LPG cylinders in accordance with EN 14140 or equivalent standard;

Annex C for specific requirements for welded aluminium LPG cylinder;

Annex D for specific requirements for composite LPG cylinders.

6.2 Proof pressure test

6.2.1 General

The test shall consist of one of the proof pressure tests described in 6.2.2 and 6.2.3. Proof pressure test according to 6.2.3 requires the agreement of a competent authority. The pneumatic proof test as described in 6.2.3 shall only be implemented where such an operation does not entail any danger.

6.2.2 Hydraulic proof pressure test

6.2.2.1 General

A liquid shall be used as the test medium.

6.2.2.2 Preparation of cylinders

a) Cylinders shall be depressurized in a safe and controlled manner before proceeding.

b) Inspection maintenance and scrapping of valves shall be in accordance with EN 14912.

c) Cylinders with inoperative or blocked valves shall be transferred to a place for safe valve removal.

d) The external surface of the cylinder shall be in such condition that any leak can be detected. If the cleaning method involves the wetting of the outside surface or if the outside surface is wet due to outdoor storage conditions, the outside surface shall be completely dried before commencing the test procedure.

6.2.2.3 Test equipment

Pressure gauges that are used to read the cylinder test pressure shall be in accordance with EN 837-1 and EN 837-3 accuracy class 1,6 or better. They shall be calibrated or checked for accuracy against a master gauge at regular intervals and in any case not less frequently than once a month. The master gauge shall be re-calibrated in accordance with national requirements.

The design and installation of the equipment and the cylinders connected to it shall ensure that no air is trapped in the system.

All joints within the system shall be leak tight.

A device shall be fitted to the test equipment to ensure that no cylinder is subjected to pressure in excess of its test pressure by more than the tolerance given in 6.2.2.4.

The test equipment shall not restrict the expansion of the cylinder.


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6.2.2.4 Procedure

a) Cylinder shall be positioned so that the welds are visible during the test.

b) Pressure of the test shall be at least the minimum test pressure defined in ADR for the relevant product.

c) Pressure shall be increased gradually in the cylinder until the test pressure is reached.

d) Test pressure shall not be exceeded by more than 20 % or 6 bar, whichever is the least. More than one cylinder can be tested at a time provided they all have a test pressure within the tolerance specified. If the cylinder is tested at a higher pressure than that marked, the owner of the cylinder shall calculate the maximum pressure not to be exceeded to ensure that the general membrane stress in the cylinder wall does not exceed 95 % of the guaranteed minimum yield strength of the material used in the finished cylinder.

e) Test pressure shall be held for the time necessary to inspect the cylinder and check it out for any leak and/or other defects, but not less than 15 s.

f) If there is leakage in the pressure system, it shall be corrected and the cylinders re-tested.

g) Cylinders, that do not leak or show any visible permanent distortion after the pressure has been released, shall be deemed to have passed this test. Cylinders, showing visible defects, shall be examined by a competent person.

h) Cylinders that fail shall be rejected.

NOTE If a cylinder leaks through a pinhole at the weld, it should be examined by a competent person to determine whether it can be repaired by welding or rendered unserviceable. Welding or repairing should be carried out in accordance with the manufacturer’s requirements. These types of repairs are not permitted by the ADR.

6.2.3 Pneumatic proof test and leak test


a) Cylinders shall be depressurised in a safe and controlled manner before proceeding.

b) Cylinders with inoperative or blocked valves shall be brought to a place for safe valve removal.

c) Valves shall be removed from cylinders. For inspection, maintenance and scrapping of cylinder valves see EN 14912.

NOTE The valve can be fitted before the proof test or leak test, see 7.2.

d) Repainting before the pneumatic test shall be limited to a primer coat. The finishing coat shall be applied after the test in order not to mask potential leaks.

6.2.3.2 Procedure

6.2.3.2.1 Proof test

a) Cylinders shall be tested in a safe enclosure to protect against rupture under pneumatic pressure. Adequate procedures and measures (e.g. hearing protection) shall be adopted to protect personnel in charge of the test.

b) Pressure of the test shall be at least the minimum test pressure defined in ADR for the relevant product.


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c) Where a separate pressure relief valve is fitted, an adequate margin of safety shall be maintained between the pneumatic proof test pressure and the pressure setting of the pressure relief valve. Where necessary, the pressure relief valve shall be removed and the port plugged for testing.

d) After the cylinder has been placed in a safe enclosure, it shall be charged with the pneumatic test medium (e.g. air, nitrogen) to the test pressure and held at that pressure for 5 s to 7 s. The gas to be used for testing shall be non-flammable to avoid any internal explosion risk. The cylinder passes the proof test if it does not burst. The cylinder shall then be isolated from the pressure source.

NOTE Consideration should be given to the need to avoid corrosion if full water immersion is used.

6.2.3.2.2 Leak test

a) Pressure shall be reduced to a pressure not less than 6 bar. The pressure drop shall be monitored in a safe and controlled manner.

b) Reduced pressure shall be held for the time necessary to inspect the cylinder and checked it out for any leaks.

c) Cylinders that do not leak or show any visible permanent distortion after the pressure has been released shall be deemed to have passed this test.

d) Cylinders that fail shall be rejected.

6.3 Check of the internal condition of the cylinder

6.3.1 Check of the internal condition for welded steel LPG cylinders and LPG cylinders of alternative design and construction

6.3.1.1 General

The check shall consist of one of the two tests, either 6.3.1.2 or 6.3.1.3.

6.3.1.2 Internal visual inspection

6.3.1.2.1 Preparation of cylinders

a) Cylinders shall be depressurised in a safe and controlled manner before proceeding.



6.3.1.2.2 Procedure

a) After removing the residual liquid, where necessary, and any other foreign matter from the interior, cylinders shall be inspected internally for any sign of corrosion or other defects that can affect their integrity, using a safe inspection lighting system with appropriate internal illumination (e.g. an endoscope).

b) Cylinders showing signs of internal corrosion, except those having only a film layer of surface rust, shall be removed for further detailed evaluation in accordance with Table A.2 and Table B.2 as appropriate.

c) If cleaning is required, care shall be taken to avoid damaging the cylinder walls. Cylinders shall be re-inspected after cleaning.


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6.3.1.3 Check of the minimal wall thickness

The wall thickness shall be measured (e.g. using ultrasonic method), according to a procedure agreed with the competent authority, in sufficient number of places in order to guarantee the minimum wall thickness of the entire cylinder. The measurements shall be compared to the minimum calculated wall thickness. If one of the measurements is lower than the minimum calculated wall thickness, the cylinder shall be rejected.

The minimum calculated wall thickness shall be provided by the owner of the cylinder.

6.3.2 Check of the internal condition of aluminium and composite cylinders

6.3.2.1 General

An internal visual inspection shall be performed to detect internal defects or the presence of foreign matter in non-transparent cylinders.


a) Cylinders shall be depressurized in a safe and controlled manner before proceeding.



d) Care shall be taken when clamping composite cylinders in order to avoid damage.

NOTE For transparent composite cylinders, the internal visual inspection can be made from outside without depressurizing the cylinder or removing the valve.

6.3.2.3 Procedure

a) After removing residual liquid, where necessary, and any other foreign matter from the interior, cylinders shall be inspected internally for any sign of corrosion or other defects that can affect its integrity, using a safe inspection lighting system with appropriate internal illumination (e.g. an endoscope).

b) Cylinders showing signs of internal defects, e.g. cracks, damaged liner, internal corrosion or chemical attack, shall be scrapped.

c) If cleaning is required, care shall be taken to avoid damaging the cylinder walls. Cylinders shall be re-inspected after cleaning.

6.4 Inspection of cylinder threads

6.4.1 General

When the valve (and any other fitting) is removed during periodic inspection, the cylinder threads shall be inspected in accordance with 6.4.2, 6.4.3 and 6.4.4.

6.4.2 Internal threads

The internal threads of the cylinder shall be visually inspected and cleaned from any foreign matter. The leak-tightness of the valve onto the cylinder shall be checked after valving.

NOTE This can be performed at the test station or at the filling station.


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6.4.3 External threads

External neck threads, which are required for operational reasons, shall be examined for integrity and for thread damage.

6.4.4 Damaged threads

Where necessary and where the design permits, damaged threads shall be repaired by a competent person or the cylinder shall be rendered unserviceable in accordance with EN 12816.

6.5 Inspection of valves

Valves shall be inspected, repaired, refurbished or scrapped in accordance with EN 14912."

7 Final operations

7.1 Drying

After hydraulic testing, effective precautions shall be taken to prevent internal corrosion.

7.2 Valving

A new, inspected or refurbished valve, suitable for the intended use, shall be fitted to the cylinder using a sealing material/system and the optimum torque necessary to ensure a seal between the valve and the cylinder.

The torque applied shall be consistent with both the cylinder and valve manufacturer’s recommendations.

New valves shall be in accordance with !EN ISO 14245 or EN ISO 15995".

Inspection or refurbishing of valves shall be in accordance with EN 14912.

!The leak-tightness of the valve (or any other fitting) onto the cylinder shall be checked after valving.

NOTE This can be performed at the test station or at the filling station."

7.3 Tare !!!!mass""""

The tare !mass" or indication of tare !mass" of the cylinder shall be re-established if any modification or re-valving has been made that affects the tare !mass" of the cylinder.

If the new tare indication is different from the old tare indication, it shall be marked on the cylinder and the former tare shall be made unreadable.

7.4 Marking

After successful completion of the periodic inspection, each cylinder shall be legibly and durably marked in accordance with EN 14894.

NOTE In case of periodic inspection conducted !on protected cylinders" in accordance with !G.2.3", special provisions for marking/registration may be defined and agreed by the competent authority.

7.5 Purging

Air shall be removed from the cylinder, e.g. by evacuation or by displacement with LPG.


EN 1440:2008+A1:2012 (E)

17

NOTE This may be performed at the test station or at the filling station.

8 !Repair of LPG welded steel cylinders

8.1 Major repairs

Major repairs such as dedenting, boss realignment, replacement of foot rings and shrouds can be carried out, provided this will not impair the integrity of the cylinder. All corrosion products shall be removed prior to repair.

NOTE If during the pressure test or at visual inspection pinholes are detected at the weld, the cylinder should be rendered unserviceable in accordance with EN 12816.

8.2 Minor repairs

Minor repairs (e.g. reforming damaged shrouds, carrying handles) not involving welding or hot-work on pressure containing parts can be carried out provided the integrity of the cylinder is not impaired.

8.3 Requirements for repair

Major repairs as defined in 8.1 shall be performed by a competent repair person following an approved procedure. After such repairs, which can involve a high temperature (i.e. greater than 300 °C), a stress relieving or normalizing heat treatment shall be performed if required by the gas cylinder design standard. The cylinder shall finally be proof tested in accordance with and inspected as necessary for the intended gas service."

9 Records

The organisation operating the testing station shall maintain records of the quality system, inspection reports and test data, calibration data and reports concerning the qualifications or approvals of the competent persons.

Inspection reports and test data for cylinders shall be kept and maintained by the organisation operating the testing station at least for the retest period plus 2 years.

An inspection report or test data can cover one or more cylinders.


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18

Annex A (normative)

Specific requirements for welded and brazed steel LPG cylinders

Rejection limits for physical, material and other defects on the cylinder shell are given in Table A.1, Table A.2 and Table A.3.

Table A.1 — Physical defects in the cylinder wall

Defect Description Rejection limit

Bulge Visible swelling of the cylinder All

Dent A depression in the cylinder that has neither penetrated nor removed metal, when its width at any point is greater than 2 % of the external cylinder diameter.

When the depth of the dent exceeds 25 % of its width at any point a.

Cut or gouge A sharp impression where metal has been removed or redistributed.

Where the original calculated wall thickness is known: depth of cut or gouge is such that the undamaged (remaining) wall is less than the minimum calculated wall thickness.

Where the original calculated wall thickness is not known: all.

Dent containing cut or gouge

A depression in the cylinder within which there is a cut or gouge.

When the size of the dent or cut or gouge exceeds the dimensions for rejection as an individual defect.

Crack A split or rift in the cylinder shell. All

Lamination Layering of the material within the cylinder wall appearing as a discontinuity, crack, lap or bulge at the surface.

All

a Appearance (e.g. sharp dent) and location (e.g. on shoulder of the cylinder) also play a part in the evaluation of dent severity.


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Table A.2 — Corrosion on the cylinder wall

Type of corrosion

Description Rejection limit

Isolated corrosion pits

A pitting of metal occurring in isolated areas at a concentration not greater than 1 pit per 500 mm2 of surface area.

When the depth of discrete pits exceeds 0,6 mm (a greater depth of corrosion can be accepted provided that depth of corrosion does not reduce the wall thickness below the minimum calculated wall thickness).

Area corrosion Reduction in wall thickness over an area not exceeding 20 % of the cylinder surface.

When the depth of penetration of any pit exceeds 0,4 mm (a greater depth can be accepted provided that the depth of corrosion does not reduce the wall thickness below the minimum calculated wall thickness).

General corrosion

A reduction in wall thickness over an area exceeding 20 % of the cylinder surface.

When the depth of penetration of any pit exceeds 0,2 mm. A greater depth can be accepted providing that the depth of corrosion does not reduce the wall thickness below the minimum calculated wall thickness.

Chain pitting or line or channel corrosion

A series of pits or corroded cavities of limited width along the length or around the cylinder circumference.

1) When the total length of corrosion in any direction exceeds 50 % of the circumference of the cylinder; or 2) When the depth of penetration exceeds 0,4 mm. A greater depth can be accepted providing that the depth of corrosion does not reduce the wall thickness below the minimum calculated wall thickness; or 3) When the depth of corrosion cannot be measured.

Crevice corrosion

Crevice corrosion occurs in the area of the intersection of the foot-ring or shroud with the cylinder.

When the depth of penetration exceeds 0,4 mm or when the depth of corrosion cannot be measured

Table A.3 — Other defects


Depressed bung Damage to the bung which has altered the profile of the cylinder.

A limited level of depression/alignment deviation, as agreed by the competent body

Otherwise, all

Arc or torch burns

Burning of the cylinder base metal, a hardened heat affected zone, the addition of extraneous weld metal, or the removal of metal by scarfing or cratering.

All

Fire damage a Excessive general or localized heating of a cylinder usually indicated by:

– charring or burning of paint;

– fire damage of the metal;

– distortion of the cylinder;

– melting of metallic valve parts;

– melting of any plastic components, e.g. date ring, plug or cap.

All

Damaged foot-ring

Not firmly attached foot-ring All

Badly deformed foot-ring unstable or unbalanced cylinder

Damaged shroud

Loose or badly deformed shroud Preventing proper operation or protection of valve

a If paint is only superficially charred, a cylinder may be accepted by a competent person.


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Annex B (normative)

Specific requirements for welded steel LPG cylinders in accordance with

EN 14140:2003+A1 or the equivalent standard

B.1 General

The owner of the cylinder (or their authorized representative) shall provide the testing station with rejection criteria for the physical and material defects and heat damage to the cylinder.

The rejection/ acceptance criteria will be established at the time of the type approval.

These criteria will be established by the manufacturer, taking into account the design conditions of the cylinder (e.g. wall thickness, material). See EN 14140.

The descriptions for defects on carbon steel cylinders are shown in Table B.1, Table B.2 and Table B.3. The completed tables for stainless steel cylinders are shown in Table B.4, Table B.5 and Table B.6.

B.2 Procedure for establishing rejection criteria carbon steel cylinders

The rejection criteria for the defects described in Table B.1, Table B.2 and Table B.3 shall be established in accordance with the following procedure for each design of cylinder as defined in EN 14140:2003+A1:

for each defect, four cylinders with the same defect shall be tested. The size of this defect is recorded. If the defects of the cylinders are different sizes, the size of the smaller defect shall be recorded;

two cylinders shall be submitted to the burst test as described in EN 14140:2003+A1 and two cylinders shall be submitted to the fatigue test as described in EN 14140:2003+A1;

if the cylinders pass the tests, the defect is acceptable. The rejection limit can then be defined by the size of that defect;

when all rejection criteria have been established for a design of cylinder as defined in EN 14140:2003+A1:2006, Table B.1, Table B.2 and Table B.3 shall be completed by the owner/manufacturer of the cylinder.


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Table B.1 — Physical defects in the cylinder wall

Defects Description Rejection limit

Bulge Visible swelling of the cylinder. All

Dent A depression in the cylinder that has neither penetrated nor removed metal, and its width at any point is greater than 2 % of the external cylinder diameter.

See clause B.2 a


See clause B.2

Intersecting cut or gouge The point of intersection of two or more cuts or gouges.

All

Dent containing cut or gouge A depression in the cylinder within which there is a cut or gouge.




All


Table B.2 — Corrosion on the cylinder wall


Isolated corrosion pits A pitting of metal occurring in isolated areas at a concentration not greater than 1 pit per 500 mm2 of surface area.

See clause B.2


See clause B.2

General corrosion A reduction in wall thickness over an area exceeding 20 % of the cylinder surface.

See clause B.2

Chain pitting or line or channel corrosion


See clause B.2

Crevice corrosion Crevice corrosion occurs in the area of the intersection of the foot ring or shroud with the cylinder.

See clause B.2


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Table B.3 — Other defects



All or a limited level of depression/alignment deviation as agreed with the competent body.

Arc or torch burns Burning of the cylinder base metal, a hardened heat affected zone, the addition of extraneous weld metal, or the removal of metal by scarfing or cratering.

All







All

Damage of handle if fitted Excessive deforming of the handle If there is a risk of an injury e.g. finger cut.

Damaged foot-ring Not firmly attached foot-ring All

Badly deformed foot-ring Unstable or unbalanced cylinder.

Damaged shroud Loose or badly deformed shroud Preventing proper operation or protection of valve.


B.3 Rejection criteria for stainless steel cylinders

Rejection criteria for defects on stainless steel cylinders are described in Table B.4, Table B.5 and Table B.6.

These tables shall apply to cylinders manufactured from stainless steel in accordance with EN 10028-7.

If required, the cylinder shall be cleaned and have all loose coatings or labels, corrosion products, tar, oil or other foreign matter removed from its external surface.


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Table B.4 — Stainless steel cylinders – physical defects in the cylinder wall



Dent A depression in the cylinder that has neither penetrated nor removed metal, and its width at any point is greater than 4 % of the external cylinder diameter

When the depth of the dent exceeds one third of its width at any point. Consideration of appearance and location also plays a part in the evaluation of dents a.

Cut or gouge A sharp impression where metal has been removed or re-distributed


Where the original calculated wall thickness is not known: All

Intersecting cut or gouge The point of intersection of two or more cuts or gouges

All


A depression in the cylinder within which there is a cut or gouge


Crack A split or rift in the cylinder shell All


All


Table B.5 — Stainless steel cylinders – corrosion on the cylinder wall



A pitting of metal occurring in isolated areas.

All

Area corrosion and general corrosion

Reduction in the wall thickness over an area exceeding 5 % of the cylinder surface.

All

Crevice corrosion Crevice corrosion occurs in the area of the intersection of the foot ring or shroud with the cylinder.

When the depth of penetration exceeds 0,2 mm or when the depth of corrosion cannot be measured.


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Table B.6 — Stainless steel cylinders – other defects


Depressed bung Damage to the bung which has altered the profile of the cylinder

A limited level of depression/alignment deviation, as agreed by the competent body.

Otherwise, all

Arc or torch burns Burning of the cylinder base metal, a hardened heat affected zone, the addition of extraneous weld metal, or the removal of metal by scarfing or cratering.

All

Fire damage Excessive general or localized heating of a cylinder usually indicated by:

fire damage to the metal;

distortion of the cylinder;

melting of metallic valve parts;

melting of any plastic components e.g. data ring, plug or cap.

All

Damage of handle Excessive deforming of the handle If there is a risk of an injury e.g. finger cut.

Damaged foot-ring Not firmly attached foot-ring All

Badly deformed foot-ring Unstable or unbalanced cylinder



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25

Annex C (normative)

Specific requirements for welded aluminium LPG cylinders

Rejection limits for physical, material and other defects on the cylinder shell are given in Table C.1, Table C.2 and Table C.3.

Table C.1 — Physical defects in the cylinder wall



Dent A depression in the cylinder that has neither penetrated nor removed metal, when its width at any point is greater than 2 % of the external cylinder diameter.

When the depth of the dent exceeds 25 % of its width at any point a



Where the original calculated wall thickness is not known: all.


A depression in the cylinder within which there is a cut or gouge.




All



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Table C.2 — External corrosion

Type of corrosion

Description Rejection limit

General corrosion

A reduction in wall thickness over an area exceeding 20 % of the cylinder surface.

Original surface of the metal is no longer recognizable; or

depth of penetration exceeds 10 % of the original thickness of wall;or

The wall thickness is less than the minimum design wall thickness.


depth of penetration exceeds 20 % of the original thickness of the cylinder wall; or

The wall thickness is less than the minimum design wall thickness.

Chain pitting or

line or channel corrosion


A total length of corrosion in any direction exceeds the diameter of the cylinder; or

depth exceeds 10 % of the original wall thickness; or

wall thickness is less than the minimum design wall thickness.


Corrosion forming isolated craters, without significant alignment.

If the diameter of a pit is greater than 5 mm, refer to the "area corrosion" row.

If the diameter of a pit is less than 5 mm, the latter shall be assessed as carefully as possible in order to check the remaining thickness of the wall or base is not less than the minimum design wall thickness.

Table C.3 — Other defects



All, except a limited level of depression/alignment deviation, as agreed by the competent body.

Arc or torch burns Burning of the cylinder base metal, a hardened heat affected zone, the addition of extraneous weld metal, or the removal of metal by scarfing or cratering

All







All

Damaged foot-ring

Not firmly attached foot-ring All

Badly deformed foot-ring unstable or unbalanced cylinder




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27

Annex D (normative)

Specific requirements for composite LPG cylinders

D.1 Establishment of rejection criteria

D.1.1 General

The rejection/ acceptance criteria will be established at the time of the type approval.

The owner of the cylinder (or their authorized representative) shall provide the testing station with rejection criteria for the physical and material defects and heat damage to the cylinder/casing.

These criteria will be at least those established by the manufacturer, taking into account the design conditions of the cylinder (e.g. nature of the casing if any, nature and type of the fibre and of the resin system). See EN 14427.

!NOTE RID and ADR require that these criteria are acceptable to the competent authority."

The descriptions for defects on cylinders are shown in Table D.1.

D.1.2 Procedure

The rejection criteria for the defects described in Table D.1 shall be established in accordance with the following procedure for each design of cylinder as defined in EN 14427.

For each defect, four cylinders with the same defect shall be tested. The size of this defect is recorded. If the defects of the cylinders are different sizes, the size of the smaller defect shall be recorded.

Two cylinders shall be submitted to the burst test as described in EN 14427 and two cylinders shall be submitted to the pressure cycle test as described in EN 14427.

If the cylinders pass the tests, the defect is acceptable. The rejection limit can then be defined by the size of that defect.

When all rejection criteria have been established for a design of cylinder as defined in EN 14427:2004, Table D.1 shall be completed by the owner/manufacturer of the cylinder. Clause D.2 shows an example of a completed table.


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Table D.1 — Rejection criteria


Abrasion damage or damage from cuts

Abrasion damage caused by wearing, grinding or rubbing material away by friction.

Cuts or gouges caused by contact with sharp objects in such a way as to cut into the composite, reducing its thickness at that point.

See D.1.2

Delamination and

impact damage

Inter-laminar delamination where there is a separation of layers of strands.

Intra-laminar delamination where there is a separation between strands within the same layer.

Impact damage appearing as hairline cracks in the resin or delamination or cuts of the composite material.

See D.1.2

Chemical damage

Chemical attack appearing as the dissolution of the resin matrix surrounding the fibres, where the cylinder surface is sticky.

If the casing is not drainable, chemical attack might appear inside the casing.

See D.1.2

Damage of casing

Minor damage that does not affect the protecting function of the casing is acceptable. If it cannot be established that the cylinder is unaffected, the cylinder shall be put aside for further investigation.

Unacceptable damage is, for example, a broken casing. The casing is then to be removed and the cylinder inspected underneath. A damaged cylinder shall be rejected. If the cylinder is not damaged, a new casing can be assembled.

Heat/fire damage of casing or cylinder

Heat or fire damage evident by discolouration, scarring or burning of the composite overwrap, casing, labels and non-metallic components of the valve.

See D.1.2

Other defects See D.1.2, if applicable

NOTE 1 Inter-laminar delamination is a separation of layers of strands, while intra-laminar delamination is separation between strands within the same layer.

NOTE 2 For cylinders with liners, an area with no adhesion between liner and composite is not to be regarded as delamination.

D.2 Examples of rejection criteria

The rejection criteria given in Table D.2 are an example applicable to cylinders without liner manufactured from glass fibre and vinylester/epoxy fitted with a thermoplastic casing.

NOTE References to percentages will be replaced in absolute values (in mm) for particular cylinder design.


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Table D.2 — Examples of rejection criteria


Abrasion damage or damage from cuts

Abrasion damage caused by wearing, grinding or rubbing material away by friction, see Figure D.1.

Cuts or gouges caused by contact with sharp objects in such a way as to cut into the composite, reducing its thickness at that point, see Figure D.2.

Depth exceeds 10 % of composite overwrap thickness, or

Total length of cut(s) exceeds 50 % of the diameter of the cylinder, or

Damaged area maximum diametera exceeds 50 % of the diameter of the cylinder.

Cuts that do not sever a fibre are not included in the above.

Chemical damage

Chemical attack appearing as the dissolution of the resin matrix surrounding the fibres, where the cylinder surface is sticky.

If the casing is not drainable, chemical attack might appear inside the casing.

Chemical attack resulting in damage to the resin matrix surrounding the fibres.

Damage of casing

Broken casing. The casing shall be removed and the cylinder inspected. A damaged cylinder shall be rejected. If the cylinder is not damaged, a new casing can be assembled. See Figure D.6.

(Minor damage that does not affect the protecting function of the casing is acceptable. Acceptable damage can be, for example, small cracks, see Figure D.5. If it cannot be established that the cylinder is unaffected, the cylinder shall be put aside for further investigation).

Heat/fire damage of casing or cylinder

Heat or fire damage evident by discolouration, scarring or burning of the composite overwrap, casing, labels and non-metallic components of the valve.

Visible damage from heat and/or fire. See Figure D.7.

Corrosion of bung

Severe corrosion.

a The maximum diameter of the damage area is the diameter of the smallest circle that includes the damaged area. b It may also appear as a whitish patch like a blister or an air bubble beneath the surface. See Figure D.4.

NOTE Inter-laminar delamination is a separation of layers of strands, while intra-laminar delamination is separation between strands within the same layer intra-laminar delamination appears as a whitish patch like a blister or air bubble beneath the surface. See Figure D.3 and Figure D.4 for examples.


EN 1440:2008+A1:2012 (E)

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Figure D.1 — Damage from abrasion

Figure D.2 — Damage from cuts

25 mm

100 mm


EN 1440:2008+A1:2012 (E)

31

Figure D.3 — Impact damage in combination with delamination and surface defects

Figure D.4 — Delamination with no signs of surface damage

25 mm

25 mm


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32

Figure D.5 — Defect casing

Figure D.6 — Defect casing: Broken casing


EN 1440:2008+A1:2012 (E)

33

Figure D.7 — Heat and fire damage


EN 1440:2008+A1:2012 (E)

34

Annex E !(informative)"

!Requirements for 15-year periodic inspection interval for welded and

brazed steel cylinders manufactured before 2015-01-01"

E.1 General

For a cylinder to qualify for a 15-year time interval, all of the following specific requirements shall apply:

a) Cylinder shall be filled in accordance with the criteria contained in EN 1439 or an equivalent standard as approved by a competent authority with particular emphasis on:

cylinder identification (e.g. design code, tare !mass", mark of the competent body) (see EN 14894);

external cylinder condition (see 5.2);

cylinders are designed, manufactured and tested to EN 1442, or an equivalent;

there is a system of external protection against corrosion which is being maintained.

b) LPG quality shall comply with the limitations on corrosive contaminants specified in ISO 9162.

c) Cylinders shall be under the control of a competent gas organisation responsible for their distribution, filling and maintenance. The concept of control of cylinders is as stated in E.2.

d) For cylinders designed according to EN 14140:2003+A1, it is necessary to have more than 15 years experience related to the cylinder type.

e) Other conditions to be meet are listed in E.3.

E.2 Concept of control

a) Cylinders shall be owned by and under the responsibility for checking, filling and maintenance of a competent gas organisation, that loans or hires them to distribution undertakings, consumers or other users under the conditions used in E.3;

or

b) Cylinders are not owned by, but their distribution, filling and maintenance are under the responsibility of a competent gas organisation;

and

The responsible competent gas organisation may contract the filling, maintenance and/or testing to other competent organisations, ensuring that the cylinders are filled, maintained and tested only as contracted in accordance with the procedures of that competent gas organisation.


EN 1440:2008+A1:2012 (E)

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E.3 Conditions

The following conditions shall be fulfilled:

a) Responsible competent gas organisation shall ensure that the cylinders are returned for filling, maintenance and/or testing to the responsible competent gas organisation or an authorized contractor, or shall be exchanged for a full cylinder at a retail outlet serviced by the responsible competent gas organisation or an authorized contractor.

b) Responsible competent gas organisation or their contractor shall have established appropriate filling, maintenance and test facilities under their control.

The responsible competent gas organisation shall have a policy of taking all necessary measures to ensure that their cylinders are filled, maintained and tested only at the facilities stated in b).

!NOTE 15-year periodic inspection interval is allowed under conditions of ADR 2009 P200 v which takes precedence over any clause of this annex."


EN 1440:2008+A1:2012 (E)

36

Annex F (informative)

Guidance on requirements for 10-year periodic inspection interval on

composite cylinders

For a cylinder to qualify for a 10 year time interval, all of the following requirements shall apply:

a) Each type of cylinder as defined in EN 14427:2004, A.2.1 shall undergo and pass the following tests:

100 cylinders older than 5 years shall be picked at random;

80 cylinders shall be subjected to and pass a burst test in accordance with test number 5 in EN 14427;

20 cylinders shall be subjected to and pass a fatigue test in accordance with test number 6 in EN 14427.

b) Cylinder shall be filled in accordance with the criteria contained in EN 14763 or an equivalent standard approved by a competent authority with particular emphasis on:

cylinder identification (e.g. design code, tare !mass", mark of the competent body) (see EN 14894);

external cylinder condition (see 5.2).

c) cylinders are designed, manufactured and tested to EN 14427, or an equivalent standard approved by a competent authority The LPG quality shall comply with the limitations on corrosive contaminants specified in ISO 9162.

d) Cylinders shall be under the control of a competent gas organisation responsible for their distribution, filling and maintenance. The concept of control of cylinders is as stated in E.2.

e) Other conditions to be met are listed in E.3.


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37

Annex G !(normative)"

Periodic inspection procedure for a particular design of protected

cylinder

G.1 Scope and cylinder description

This annex is applicable to polyurethane protected cylinders (see Figure G.1).

14,42

2

Key 1 Cap 2 Valve 3 Tare indication 4 Electronic identification tag 5 Polyurethane protection against impact and corrosion 6 Steel receptacle 7 Identification marks

Figure G.1 —Typical polyurethane protected cylinder


EN 1440:2008+A1:2012 (E)

38

G.2 Cylinders design and manufacturing requirements

G.2.1 Steel cylinder

!The metallic cylinder shall be designed and manufactured in accordance with EN 1442 or EN 14140."

G.2.2 External protection

The detailed design, manufacture and testing of polyurethane protection against impact and corrosion shall be approved by a competent authority.

G.2.3 Marking and recording requirements

The cylinders shall be under the control of a competent gas organisation responsible for their distribution, filling and maintenance.

Each cylinder shall be fitted with an individual resilient identification electronic tag or any equivalent device linked to an electronic database.

The database shall be maintained under the responsibility of the competent gas organisation.

The database system shall record:

identification of each cylinder;

manufacturing information of each cylinder;

status of each cylinder regarding periodic inspection;

tare !mass" of each cylinder;

segregation before filling of any identified cylinder or batches of cylinders for any reason (e.g., periodic inspection, sampling).

G.3 Inspection at filling

Cylinders shall be individually checked before, during and after each filling in accordance with EN 1439.

G.4 Periodic destructive tests on batch sampling

G.4.1 Testing procedure

A periodic inspection testing procedure shall be established from this annex and agreed with the competent authority.

Testing shall occur:

after 3 years of service, and

every n years after the first tests.

"n" shall be established as result of experience of the ability of the polyurethane protection to maintain its properties against impact and corrosion. Initially "n" shall be 5 years and may be extended later to 10 years, or 15 years for cylinders meeting the requirements of Annex E with the agreement of the competent authority.


EN 1440:2008+A1:2012 (E)

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G.4.2 Destructive tests

The destructive test shall include at least the following:

!burst test in accordance with EN 1442 or EN 14140, and"

peeling and corrosion test in accordance with !EN ISO 4628-3".

Additional adhesion destructive test in accordance with !EN ISO 4624" shall be conducted if required by the competent authority.

G.4.3 Rejection criteria and batch sampling

Rejection criteria and sampling levels shall be in accordance with Table G.1.

Table G.1 — Batch sampling

!

Test interval (years)

Test type Standard Rejection criteria

Batch sampling level Test results

3 Burst test EN 1442 Burst pressure <70 bar

or

Volumetric expansion

< 12 %

33 Q or 200/Q

whichever is lower,

and

with a minimum of 20 per batch (Q)

If any test fails, repeat tests replacing Q with monthly production q and test for each month. For any month's tests having failures, the whole production for that month shall be rejected.

Peeling and

corrosion

EN ISO 4628-3 Max corrosiongrade :

Ri2

Q/1 000

Every n Burst test EN 1442 Burst pressure <70 bar

or

Volumetric expansion

< 12 %

36 Q or 100/Q

whichever is lower,

and

with a minimum of 40 per batch (Q)

Peeling and

corrosion

EN ISO 4628-3 Max corrosiongrade :

Ri2

Q/1 000

Q Represents the total number of cylinders made by manufacturer in the same year.

q Represents a continuous production batch.

"


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G.4.4 Periodic inspection tests reports and records

Periodic inspection reports shall be made available to the competent authority, and then with their agreement (if required), the database is updated.


EN 1440:2008+A1:2012 (E)

41

Annex H (normative)

!Periodic inspection procedure for cylinder populations not covered

by the ADR

Procedures for periodic inspection of cylinder populations not covered by ADR shall consist of inspections as described in Table H.1 plus a replacement of the valve or an inspection of the valve in accordance with EN 14912.

Table H.1 — Procedures for periodic inspection

Cylinders Procedures

Welded and brazed steel LPG cylinders a External visual inspection as described in 6.1 and,

Additionally, at least one of the tests described in 6.2 and 6.3. orAnnex J b

Welded aluminium LPG cylinders and composite LPG cylinders.

Procedures are identical to those defined in 5.1.2.

a An alternative procedure for periodic inspection of protected cylinders is described in Annex G.

b Only cylinders where the wall thickness is equal to or greater than the minimum calculated wall thickness and the design burst pressure is known or can be shown to be at least 35 bar for commercial butane cylinders and 70 bar for commercial propane cylinders can be exempted from the proof pressure test described in 6.2.

Alternative test described in Annex J. is only applicable to cylinders with less than 6,5 l water capacity.

"


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Annex I (informative)

!Requirements to be fulfilled to extend period between two periodic

inspections to 15 years for RID/ADR welded steel LPG cylinders

I.1 General

The interval between periodic inspections may be extended to 15 years if the owner of a group of cylinders has granted the agreement of the competent authority where it can be ensured that the requirements of this annex are fulfilled.

NOTE A group of cylinders is defined by the production dates of identical cylinders for a period, during which the applicable provisions of ADR and of the technical code accepted by the competent authority have not changed in their technical content.

I.2 Design and manufacturing

Cylinders manufactured since 1 January 1999 shall have been manufactured in conformity with the following standards:

EN 1442, or

EN 13322-1, or

Annex I, parts 1, 2 and 3 of Council Directive 84/527/EEC.

Other cylinders manufactured before 1 January 2009 in conformity with ADR in accordance with a technical code accepted by the competent authority can be accepted for a 15 year interval, if they are of equivalent safety to the provisions of ADR as applicable at the time of application.

I.3 Operational provisions

Cylinders having been granted a 15 year interval for periodic inspection shall only be filled in filling centres applying a documented quality system to ensure that all cylinders are filled in accordance with regulation and that the requirements and responsibilities of EN 1439:2008 are fulfilled and correctly applied.

LPG quality shall comply with the limitations on corrosive contaminants specified in ISO 9162.

I.4 Periodic inspection

Cylinders shall be periodically inspected according to 5.1.2. The following additional requirements shall be fulfilled:

if a cylinder with a 15 year interval fails the hydraulic pressure test during a periodic inspection e.g. by bursting or leakage, the owner shall investigate and produce a report on the cause of the failure and if other cylinders (e.g. of the same type or group) are affected. In the latter case, the owner shall inform the competent authority which shall then decide of appropriate measures;

cylinders having been granted a 15 year interval shall only be fitted with valves designed and manufactured for a minimum 15 year period of use according to EN ISO 14245 or EN ISO 15995. After a periodic inspection, a new valve shall be fitted to the cylinder, with the exception for manually operated valves which can be re-fitted provided that the valves have been refurbished or inspected in accordance


EN 1440:2008+A1:2012 (E)

43

with EN 14912 and it can be demonstrated that they are suitable for another 15 year period of use. Refurbishment or inspection shall only be carried out by the manufacturer of the valves or in accordance with technical instruction from an organisation qualified for such work and operating under a documented quality system.

I.5 Marking

Cylinders granted a 15 year interval for periodic inspection in accordance with this paragraph shall additionally be marked clearly and legibly with "P15Y". This marking shall be removed if the cylinder is no longer authorized for a 15 year interval.

NOTE 1 The text of this annex is based on the RID/ADR special packing provision P200(12) which includes additional provisions and information and which takes precedence over any clause of this standard.

NOTE 2 The application of this annex is subject to the agreement by the competent authority."


EN 1440:2008+A1:2012 (E)

44

Annex J (informative)

!Alternative test applicable to commercial butane cylinders with less

than 6,5 l water capacity

J.1 General

CAUTION — This test is only applicable to cylinders with less than 6,5 l water capacity.

The pneumatic leak test is applicable to dedicated commercial butane cylinders whose owner shall ensure that the wall thickness is equal to or greater than the minimum calculated wall thickness and that the design burst pressure is known, or can be shown to be at least 50 bar and agreed with the competent authority.

J.2 Preparation of cylinder

J.2.1 Cylinders shall be depressurised in a safe and controlled manner before proceeding, where necessary.

J.2.2 Cylinders with inoperative or blocked valves shall be brought to a safe location for valve removal.

J.2.3 For inspection, maintenance and scrapping of cylinder valves see EN 14912.

J.3 Procedure

J.3.1 The pneumatic leak test can be carried while the valve is fitted to a pressurized cylinder. Cylinder shall be filled with a pneumatic test medium (e.g. natural gas, air, nitrogen) in such a way that the internal pressure developed in the cylinders at the time they are checked for leakage shall not be less than 7 bar.

NOTE 1 Propane vapour can also be used as the test medium.

NOTE 2 If another flammable gas than the one already in the cylinder is to be used for the test it should:

be used in such a small quantity that the product into the cylinder after filling meets the requirements of commercial butane; or

be partly or completely withdrawn from the cylinder after testing.

J.3.2 Cylinder shall be isolated from the pressure source.

NOTE To achieve this pressure the ambient temperature should be at least 20 °C.

J.3.3 Test shall consist of full immersion of the cylinder in water or an equivalent detection system. The gas tightness check shall be capable of detecting any leak from any part of the cylinder.

NOTE Consideration should be given to the need to avoid corrosion, if full water immersion is used.

J.3.4 Cylinders that do not leak or show any visible permanent distortion after the pressure has been released shall be deemed to have passed the test.

J.3.5 Cylinders that fail shall be rejected.

NOTE Annex J reflects the provisions of RID/ADR 6.2.3.5.1 which takes precedence over this annex."


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Bibliography

[1] EN 12807, Transportable refillable brazed steel cylinders for liquefied petroleum gas (LPG) — Design and construction

[2] EN 13110, Transportable refillable welded aluminium cylinders for liquefied petroleum gas (LPG) — Design and construction

[3] EN ISO 4624, Paints and varnishes — Pull-off test for adhesion (ISO 4624:2002)

!deleted text"

[4] EN ISO 8501-1, Preparation of steel substrates before application of paints and related products — Visual assessment of surface cleanliness — Part 1: Rust grades and preparation grades of uncoated steel substrates and of steel substrates after overall removal of previous coatings (ISO 8501-1:2007)

[5] EN ISO 8504, Preparation of steel substrates before application of paints and related products — Surface preparation methods (all parts)

[6] !EN ISO 16148, Gas cylinders — Refillable seamless steel gas cylinders — Acoustic emission testing (AT) for periodic inspection (ISO 16148:2006)"

[7] ADR, European Agreement concerning the international carriage of Dangerous goods by Road.

[8] RID, Regulations concerning the International Carriage of Dangerous Goods by Rail.

[9] !Council Directive 84/527/EEC of 17 September 1984 on the approximation of the laws of the Member States relating to welded unalloyed steel gas cylinders"


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