EN 1802:2002

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Ortsbewegliche Gasflaschen - Wiederkehrende Prüfung von nahtlosen Gasflaschen aus AluminiumlegierungBouteilles a gaz transportables - Contrôles et essais périodiques des bouteilles a gaz sans soudure en alliages d'aluminiumTransportable gas cylinders - Periodic inspection and testing of seamless aluminium alloy gas cylinders77.150.10Aluminijski izdelkiAluminium products23.020.30MHNOHQNHPressure vessels, gas cylindersICS:Ta slovenski standard je istoveten z:EN 1802:2002SIST EN 1802:2002en01-november-2002SIST EN 1802:2002SLOVENSKI
STANDARD
EUROPEAN STANDARDNORME EUROPÉENNEEUROPÄISCHE NORMEN 1802February 2002ICS 23.020.30English versionTransportable gas cylinders - Periodic inspection and testing ofseamless aluminium alloy gas cylindersBouteilles à gaz transportables - Contrôles et essaispériodiques des bouteilles à gaz sans soudure en alliagesd'aluminiumOrtsbewegliche Gasflaschen - Wiederkehrende Prüfungvon nahtlosen Gasflaschen aus AluminiumlegierungThis European Standard was approved by CEN on 8 November 2001.CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this EuropeanStandard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such nationalstandards 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 translationunder the responsibility of a CEN member into its own language and notified to the Management Centre has the same status as the officialversions.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 STANDARDIZATIONCOMITÉ EUROPÉEN DE NORMALISATIONEUROPÄISCHES KOMITEE FÜR NORMUNGManagement Centre: rue de Stassart, 36
B-1050 Brussels© 2002 CENAll rights of exploitation in any form and by any means reservedworldwide for CEN national Members.Ref. No. EN 1802:2002 ESIST EN 1802:2002

Gas cylinders manufactured according to National Regulations.13Annex B (normative)
Inspection periods.15Annex C (normative)
Description, evaluation of defects and conditions for rejection of seamlessaluminium alloy gas cylinders at time of visual inspection.16Annex D (normative)
Procedure to be adopted when a cylinder valve
is suspected to be obstructed.22Annex E (normative)
Cleaning of aluminium alloy gas cylinders.25Annex F (normative)
Proof pressure test of gas cylinders.26Annex G (normative)
Volumetric expansion testing of gas cylinders.27Annex H (normative)
Ultrasonic test.35Annex I (informative)
Inspection and maintenance of valves and their connections: recommendedprocedures.46Bibliography.47SIST EN 1802:2002

As far as practicable, this standard may also be applied to cylinders of less than 0,5 l water capacity.This standard specifies the requirements for periodic inspection and testing to verify the integrity of such gas cylindersto be reintroduced into service for a further period of time. It also defines a procedure to qualify existing gas cylindersfor free movement between member states of the European Union (see annex A).This standard does not apply to periodic inspection and testing of acetylene cylinders or composite (fully wrapped orhoop-wrapped) aluminium alloy cylinders.2 Normative referencesThis European Standard incorporates by dated or undated reference, provisions from other publications. Thesenormative references are cited at the appropriate place in the text, and the publications are listed hereafter. For datedreferences, subsequent amendments to or revisions of any of these publications apply to this European Standard onlywhen incorporated in it by amendment or revision. For undated references the latest edition of the publication referredto applies (including amendments).EN 473, Non-destructive testing — Qualification and certification of NDT personnel — General principles.EN 629-2, Transportable gas cylinders — 25E taper thread for connection of valves to gas cylinders — Part 2: Gaugeinspection.EN 837-1, Pressure gauges — Part 1: Bourdon tube pressure gauges — Dimensions, metrology, requirements andtesting.EN 837-3, Pressure gauges — Part 3: Diaphragm and capsule pressure gauges — Dimension, metrology,requirements and testing.EN 1089-1, Transportable gas cylinders — Gas cylinder identification (excluding LPG) — Part 1: Stampmarking.EN 1795, Transportable gas cylinders (excluding LPG) — Procedures for change of gas service.prEN 1964-2, Transportable gas cylinders — Specification for the design and construction of refillable transportableseamless steel gas cylinders of water capacities from 0,5 litre up to and including 150 litres – Part 2: Cylinders madeof seamless steel with an Rm value of 1100 MPa and above.EN 1975, Transportable gas cylinders — Specification for the design and construction of refillable transportableseamless aluminium and aluminium alloy gas cylinders of capacity from 0,5 litre up to 150 litre.EN ISO 11114-1, Transportable gas cylinders — Compatibility of cylinder and valve materials with gas contents —Part 1: Metallic materials (ISO 11114-1:1997).EN ISO 11114-2, Transportable gas cylinders — Compatibility of cylinder and valve materials with gas contents —Part 2: Non-metallic materials (ISO 11114-2:2000).EN ISO 13341, Transportable gas cylinders — Fitting of valves to gas cylinders (ISO 13341:1997).SIST EN 1802:2002

identification of cylinder and preparation for inspection and test (clause 5);-
external visual inspection (clause 6);-
internal visual inspection (clause 7);-
supplementary tests (clause 8);-
inspection of cylinder neck/shoulder (clause 9);-
pressure test or ultrasonic test (clause 10);-
inspection of valve (clause 11);-
final operations (clause 12);-
rejection and rendering cylinders unserviceable (clause 13).Where cylinders are manufactured according to National Regulations and are intended to be qualified under theTransportable Pressure Equipment Directive (TPED) for free movement and use between member states of theEuropean Union, additional requirements are specified in annex A.It is recommended that the above listed tests are performed in the suggested sequence. In particular the internalvisual examination (clause 7) should be carried out before the pressure test or ultrasonic test (clause 10).Cylinders which fail the inspection or tests shall be rejected (see clause 13). When, after the above tests, doubtsstill exist as to the extent of a defect or the condition of a cylinder, then additional tests may be performed inaccordance with clause 8, until such doubts are positively resolved or the cylinder shall be rendered unserviceable.Some cylinders rejected during periodic inspection and test may be recovered in accordance with annex C.SIST EN 1802:2002

clean and of full form;-
free of damage;-
free of burrs;-
free of cracks – examine thoroughly for evidence of cracks (see annex C);-
free of other imperfections.Cracks manifest themselves as lines which run vertically down the thread and across the thread faces. They shouldnot be confused with tap marks (thread machining marks). Special attention should be paid to the area at thebottom of the thread.9.2 Other neck and shoulder surfacesOther surfaces of the neck and shoulder shall also be examined to ensure they are free of cracks or other defects(see annex C).SIST EN 1802:2002

V
5,0±
505,0
V
20± 200> 20± 40012.4 StampmarkingAfter satisfactory completion of the periodic inspection and test, each cylinder shall be permanently markedaccording to EN 1089-1 with the present test date followed by the symbol of the inspection body or test station.12.5 Reference to next test dateThe next test date shall be shown in a clearly visible manner by an appropriate method such as a label or a discfitted between the valve and the cylinder, indicating the year of the next periodic inspection or periodic inspectionand test.12.6 Identification of contentsBefore the cylinder is reintroduced into service, the cylinder shall be marked according to the intended contents(see e.g. EN 1089-2 and EN 1089-3). If painting is required, care shall be exercised in accordance with 12.1.2. If achange of gas service is involved the requirements of EN 1795 shall be followed.12.7 RecordsDetails of the present test shall be recorded by the test station and the following information shall be available:-
owner's name;-
manufacturer's or owner's serial number;-
cylinder tare, where applicable;-
test pressure;SIST EN 1802:2002

result of test (pass or fail);-
present test date;-
identification symbol of the inspection body or the test station;-
identification of inspector;-
details of any modifications made to the cylinder by the inspector.Additionally, it shall be possible to obtain the following items of information from records, which need notnecessarily be kept on a single file, but will enable a particular cylinder to be traced. These items are:-
cylinder manufacturer;-
manufacturer's serial number;-
manufacturing specification;-
water capacity/size;-
manufacturing test date.13 Rejection and rendering cylinder unserviceableThe decision to reject a cylinder may be taken at any stage during the inspection and test procedure. If it is notpossible to recover a rejected cylinder, it shall, after notifying the owner, be made unserviceable by the testingstation for holding gas under pressure so that it is impossible for any part of the cylinder, especially the shoulder, tobe re-issued into service.In case of any disagreement, ensure that the legal implication of the contemplated action is fully understood.One or a combination of the following methods can be employed to render the cylinder unserviceable, afterensuring that the cylinder is empty and free of gas (see clause 5):-
crush the cylinder, preferably in the shoulder area, using mechanical means;-
burn an irregular hole in the top dome equivalent in area to approximately 10 % of the area of the top domeor, in the case of a thin-walled cylinder pierce in at least three places;-
cut the neck in an irregular fashion;-
cut the cylinder including the shoulder into two or more irregular pieces;-
burst in a safe manner.SIST EN 1802:2002

manufacturer;-
serial number;-
date of manufacture;-
regulation or specification to which the cylinder was manufactured;-
working pressure;-
test pressure;-
external diameter;-
minimum wall thickness;-
minimum yield stress;-
water capacity.The inspection body shall verify that this list contains all the necessary information to clearly define the cylinder(see example of production testing certificate in the relevant annex of EN 1975, for the above listed parametersonly).SIST EN 1802:2002

provided that therequirements under A.3 and A.4 as appropriate have been fully verified.A.6 Inspection reportThe inspection body shall prepare a report for each type of cylinder.All relevant certifications, new tests and inspections performed shall be attached to this report.SIST EN 1802:2002

cInformative recommendations for nextrevision of ADRPeriod (years)Period (years)Ar, N2, He, H2, Air, O2,CH4 etc.1010Self-contained breathingAir, O2, etcd5CompressedgasesGases for underwaterbreathing apparatusd2,5 (internal visual)and 5 (full) eCO1010LiquefiedgasesCO2, N2O etc.1010Corrosivegases fGases corrosive toaluminium are forbiddento be filled in aluminiumalloy cylinders (seeEN ISO 11114-1)33 (internal visual)and 5 (full) gToxic gases510Very toxicgasesAsH3, PH3 etc.55Gasmixturesa)all mixtures except b)below3, 5 or 10 years accordingto classificationa) Lowest test period of any componentb) mixtures completelyin the gaseous statecontaining toxic and/orvery toxic components.3 years for groups TC,TFC, TOC5 years for groups T, TF,TO10 years for groups A, O,Fb) For such mixtures, if the toxicity of thefinal mixture is such that LC50
a volumefraction of 200 × 10 -6, a 10 year periodapplies, and if the toxicity of the finalmixture is such that LC50
200 × 10 –6
a5 year period appliesa
The compatibility of the gas to be filled with aluminium alloys need to be checked in accordance with EN ISO 11114-1.b
This list of gases is not exhaustive. A full list of gases can be found in RID/ADR.c
These intervals conform to the 1999 edition of RID/ADR.d
Not currently listed in RID/ADR.e
For cylinders used for self-contained underwater breathing apparatus in addition to the full retest period of 5 years, aninternal visual inspection need to be performed every 2,5 years.f
For RID/ADR purposes, corrosivity is with reference to human tissue and NOT cylinder material.g For gas mixtures shown to be corrosive for the cylinder material, the time period for single corrosive gases applies.SIST EN 1802:2002

When applying the rejection criteria given in Table C.1, the conditions of use of the cylinders, the severity of the defect and safety factors inthe design shall be taken into consideration.b
Provided that after repair by a suitable metal removal technique, the remaining wall thickness is at least equal to the design minimum wallthickness.c
Some neck cracks ( 1 mm) may be repaired only in accordance with an agreed manufacturer's specification.d
If it can be clearly established that the cylinder fully complies with the appropriate specifications, altered operational and modified markingmay be acceptable and inadequate markings may be corrected, provided there is no possibility of confusion.SIST EN 1802:2002

If the bottom of the defect cannot be seen and if its extent cannot be determined using appropriate equipment,the cylinder shall be rendered unserviceable.b
If corrosion has reached limits of depth or extent, the remaining wall thickness should be checked with anultrasonic device. The wall thickness may be less than the minimum, with the acceptance of the inspection body,e.g. small (depth and extent) isolated pits. When applying the rejection criteria given in this table, the conditions ofuse of the cylinders, the severity of the defect and safety factors in the design shall be taken into consideration.c
Provided that after repair by a suitable metal removal technique, the remaining wall thickness is at least equal tothe design minimum wall thickness.SIST EN 1802:2002
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