SIST 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



SIST EN 1802:2002



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



EN 1802:2002 (E)2ContentspageForeword.3Introduction.41Scope.52Normative references.53Intervals between periodic inspection and test.64List of procedures for periodic inspection and test.65Identification of cylinder and preparation for inspection and test.76External visual inspection.77Internal visual inspection.88Supplementary tests.89Inspection of cylinder neck/shoulder.810Pressure test or ultrasonic test.911Inspection of valve.1012Final operations.1013Rejection and rendering cylinder unserviceable.12Annex A (informative)
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



EN 1802:2002 (E)3ForewordThis document EN 1802:2002 has been prepared by Technical Committee CEN/TC 23 "Transportable gascylinders", the secretariat of which is held by BSI.This European Standard shall be given the status of a national standard, either by publication of an identical text orby endorsement, at the latest by August 2002, and conflicting national standards shall be withdrawn at the latest byAugust 2002.In this standard the annexes B, C, D, E, F, G and H are normative and the annexes A and I are informative.This document has been prepared under a mandate given to CEN by the European Commission and the EuropeanFree Trade Association, and supports the objectives of the framework Directives on Transport of DangerousGoods.This European Standard has been submitted for reference into the RID and/or the technical annexes of the ADR.Therefore in this context the standards listed in the normative references and covering basic requirements of theRID/ADR not addressed within the present standard are normative only when the standards themselves arereferred to in the RID and/or the technical annexes of the ADR.According to the CEN/CENELEC Internal Regulations, the national standards organizations of the followingcountries are bound to implement this European Standard: Austria, Belgium, Czech Republic, Denmark, Finland,France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Spain,Sweden, Switzerland and the United Kingdom.SIST EN 1802:2002



EN 1802:2002 (E)4IntroductionThe principal aim of a periodic inspection and testing procedure is that at the completion of the test the cylindersmay be reintroduced into service for a further period of time.Experience of the inspection and testing of cylinders which is specified in this European Standard is an importantfactor when determining whether a cylinder should be returned into service.SIST EN 1802:2002



EN 1802:2002 (E)51 ScopeThis European Standard specifies the requirements for periodic inspection and testing of seamless aluminium alloytransportable gas cylinders (single or those from bundles) intended for compressed and liquefied gases underpressure, of water capacity from 0,5 l up to 150 l.NOTE
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



EN 1802:2002 (E)63 Intervals between periodic inspection and testIn order to ensure continued safe operation, cylinders shall be periodically submitted to inspection and test inaccordance with annex B. A cylinder shall fall due for a periodic inspection and test on its first receipt by a filler afterthe expiry of the interval in annex B.NOTETable B.1 gives a list of the intervals between periodic inspections for some gases which complies with the currentRID/ADR regulations and also gives recommendations which could be subsequently adopted by the RID/ADR regulations.Provided the cylinder has been subjected to normal conditions of use and has not been subjected to abusive andabnormal conditions rendering the cylinder unsafe, there is no general requirement for the user to return a gascylinder before the contents have been used even though the test interval may have lapsed. However it issuggested that cylinders are retested within a period not exceeding twice the time interval.In the case of cylinders used for emergency purposes (e.g. fire extinguishers, breathing apparatus), it is theresponsibility of the person in possession (owner or user) to submit it for a periodic inspection within the intervalspecified in annex B or as specified in the relevant cylinder design standard/regulation, if this is shorter.4 List of procedures for periodic inspection and testThe inspection and test shall be carried out only by competent persons who shall ensure that the cylinders are fitfor continued safe use.NOTEA competent person is a person who has the necessary technical knowledge, experience and authority to assessand approve materials for use with gases and to define any special conditions of use that are necessary. Such a person will alsonormally be formally qualified in an appropriate technical discipline.Each cylinder shall be submitted to periodic inspection and test. The following procedures form the requirementsfor such inspection and test, and are explained more fully in later clauses:-
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



EN 1802:2002 (E)7Mechanical properties of aluminium alloy cylinders can be affected by heat. Therefore, the maximum temperaturefor any operation shall be limited. (See 12.1.2.)5 Identification of cylinder and preparation for inspection and testBefore any work is carried out, the relevant cylinder data (e.g. see EN 1089-1) and its contents and ownership shallbe identified.The cylinders shall be depressurised and emptied in a safe, controlled manner before proceeding. Particularattention shall be given to cylinders containing flammable, oxidising and toxic gases to eliminate risks at the internalinspection stage.Cylinders with incorrect markings, unknown gas contents, or those which cannot be safely emptied of gas, shall beset aside for special handling.Cylinders with inoperative or blocked valves may be treated as outlined in annex D. Provided the requirementsabove have been complied with, and the cylinder has been depressurized safely, the valve shall be removed.Similarly in the case of cylinder bundles, not equipped with cylinder valves, the connecting tee junction shall also bechecked to determine whether the gas is able to pass freely from the cylinder to atmosphere.6 External visual inspection6.1 Preparation for external visual inspectionEach cylinder shall be cleaned and have all loose coatings, corrosion products, tar, oil or other foreign matterremoved from its external surface by a suitable method, e.g. by brushing, shot blasting (under closely controlledconditions), water jet abrasive cleaning, chemical cleaning (see annex E or consult the cylinder manufacturer) orother suitable methods. Alkaline solutions and paint strippers which are harmful to aluminium and its alloys shallnot be used. Care shall be taken at all times to avoid damaging the cylinder, or removing excess amounts ofcylinder wall.If fused nylon, polyethylene or a similar coating has been applied and is seen to be damaged, or prevents a properinspection, then the coating shall be removed. If the coating is removed by the application of heat at atemperature/time exceeding the limits specified in 12.1.2 or shows signs of heat damage, the manufacturer shall beconsulted before the cylinder is returned to service and the necessary tests and inspections carried out.6.2 Inspection procedureThe external surface of each cylinder shall then be inspected for:a) dents, cuts, gouges, bulges, cracks, laminations or excessive base wear;b) heat damage, torch or electric arc burns (as defined in Table C.1);c) corrosion (as defined in Table C.2);d) other defects such as illegible or unauthorized stamp markings, unauthorized additions or modifications;e) integrity of all permanent attachments;f) vertical stability (if relevant) (as defined in Table C.1).For rejection criteria, see annex C. Cylinders no longer suitable for future service shall be rendered unserviceable(as defined in clause 13).SIST EN 1802:2002



EN 1802:2002 (E)87 Internal visual inspectionEach cylinder shall be inspected internally, using illumination to identify any defects such as those listed in 6.2 a)and 6.2 c). Precautions shall be taken to ensure that the method of illumination presents no hazards to the testerwhilst performing the operation. Any internal liner or coating which can obstruct optimum internal visual inspection,shall be removed. Any cylinder showing presence of foreign matter or signs of more than light surface corrosionshall be cleaned internally under closely controlled conditions by shot blasting, water jet abrasive cleaning, flailing,steam jet, hot water jet, rumbling, chemical cleaning (see annex E or consult cylinder manufacturer), or othersuitable method. Care shall be taken to avoid damage to the cylinder. If cleaning is required, the cylinder shall bere-inspected after the cleaning operation.Certain hydrogen production processes can involve contamination of the gas by mercury. Any aluminium alloycylinder internally contaminated with mercury shall be rendered unserviceable.8 Supplementary testsWhere there is doubt concerning the type and/or severity of a defect found on visual inspection (see clauses 6and 7), additional tests or methods of examination may be applied, e.g. ultrasonic techniques, check weighing orother non-destructive tests. Only when all doubts are eliminated may the cylinder be further processed (seeannex C).If a hardness test is required it shall only be according to ISO 6506 or a suitable alternative method e.g.conductivity. The result shall meet, at least, the minimum required design hardness value. An alternative methodmay only be used if it was employed at the time of cylinder manufacture and recorded accordingly on the testcertificate. When the minimum design hardness value is not known, the cylinder shall be hardness tested bothbefore and after any stoving operation and there shall be no appreciable decrease in the hardness value, asagreeable to the competent person. All hardness tests shall be performed on the parallel section of the cylinder,taking adequate care to ensure that deep impressions are not formed.9 Inspection of cylinder neck/shoulder9.1 Internal neck threadThe internal neck thread of the cylinder shall be examined to ensure that it is:-
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



EN 1802:2002 (E)99.3 Damaged internal neck threadsWhere necessary, and where the manufacturer or the competent person confirms that the design of the neckpermits, threads may be re-tapped only by competent persons to provide the appropriate number of effectivethreads. After re-tapping, the threads shall be checked by the appropriate thread gauge, (e.g. for 25E threads, inaccordance with EN 629-2).9.4 Neck ring and collar attachmentWhen a neck ring/collar is attached, an examination to ensure that it is secure and free from thread damage shallbe carried out. Neck rings shall only be changed using an approved procedure. If it is found that any significantdamage to cylinder material has occurred by replacement of the neck ring/collar, the cylinder shall be renderedunserviceable. If the neck ring has been re-attached by welding or brazing, the cylinder shall be renderedunserviceable.10 Pressure test or ultrasonic test10.1 GeneralEach cylinder shall be subjected to a hydraulic or pneumatic pressure test (see 10.2) or to an ultrasonic test(see 10.3).10.2 Pressure test10.2.1 General requirementsWhen carrying out a pressure test, a suitable fluid, normally water shall be used as the test medium. The test maybe a proof pressure test (see 10.2.2) or a volumetric expansion test (see 10.2.3), as appropriate to the design ofthe cylinder. Having decided to use one particular type of test, its result shall be final. No attempt shall be made totransfer from one type of test to the other. The test pressure shall be in accordance with the stamping on thecylinder.The pressure in the cylinder shall be increased gradually until the test pressure is reached. The cylinder testpressure shall be held for at least 30 s with the cylinder isolated from the pressure source, during which time thereshall be no decrease in the recorded pressure or any evidence of any leakage. Safety precautions shall be takenduring the test.10.2.2 Proof pressure testAnnex F specifies a typical method for carrying out the test.NOTE A pneumatic pressure test may be substituted, provided approval from the relevant authority has been obtained.Take appropriate measures to ensure safe operation and to contain any energy, which is considerably more than that in thehydraulic test, which can be released.During the 30 s hold period the pressure as registered on the test gauge shall remain constant.There shall be no visible leakage or visible permanent deformation on the entire surface of the cylinder. This checkmay be made either during the 30 s hold or immediately after the pressure has been released.Any cylinder failing conforming to with the requirements of this test shall be rendered unserviceable.10.2.3 Volumetric expansion testAnnex G specifies a typical method for carrying out the test and gives details for determining the volumetricexpansion of seamless aluminium alloy gas cylinders by the preferred water jacket method or the non-water jacketmethod.SIST EN 1802:2002



EN 1802:2002 (E)10The permanent volumetric expansion of the cylinder expressed as a percentage of the total expansion at testpressure shall not exceed the percentage given in the design specification after the cylinder has been held at testpressure for a minimum period of 30 s. If this figure for permanent expansion is exceeded the cylinder shall berendered unserviceable.10.3 Ultrasonic testUltrasonic testing may be used in place of the pressure test in the procedures of periodic inspection, with theagreement of the competent person. Ultrasonic testing, if carried out, shall be in accordance with the methodspecified in annex H.11 Inspection of valveIf it is to be re-introduced into service, each valve (or tee junction for bundles) shall be inspected to verify that it willperform satisfactorily and ensure gas tightness. An example of a suitable method is given in annex I.12 Final operations12.1 Drying, cleaning and painting12.1.1 Drying and cleaningThe interior of each cylinder shall be thoroughly dried (see 12.1.2 for maximum temperature/time values to beused) by a suitable method, immediately after hydraulic pressure testing, such that there is no trace of free water.The interior of the cylinder shall be inspected to ensure that it is dry and free from other contaminants.12.1.2 PaintingCylinders are sometimes re-painted, using paints which require stoving. Plastics coatings may only be reapplied inconsultation with the cylinder manufacturer. Painting or coating shall be applied such that all markings stamped onthe cylinder are legible.Aluminium alloy cylinders are normally manufactured using precise heat treatment to obtain the final mechanicalproperties. Therefore the maximum temperature for any operation shall be limited.In no case shall the temperature of the cylinder exceed that recommended by the manufacturer since overheatingchanges the mechanical properties of the cylinder. When the cylinder's alloy/heat treatment cannot be establishedthe following requirements for non-heat treated alloy apply.For cylinders manufactured from heat treated alloys with ageing, the maximum temperature shall not exceed150 ºC. For temperatures between 100 ºC and 150 ºC the exposure time shall be limited to 30 min. If the stoving(heating) time exceeds 30 min at a temperature between 100 ºC and 150 ºC or exceeds 150 ºC then a hardnesstest shall be conducted (see clause 8).For cylinders manufactured from non-heat treated alloys the maximum temperature shall not exceed 80 ºC. Fortemperatures between 60 ºC and 80 ºC the exposure time shall be limited to 15 min. If the stoving (heating) timeexceeds 15 min at temperatures between 60 ºC and 80 ºC or exceeds 80 ºC then a hardness test shall beconducted (see clause 8).12.2 Re-valving of the cylinderThe valve shall be fitted to the cylinder using a sealing material. An optimum torque necessary to ensure both aseal between the valve and the cylinder and prevent over-stressing the neck shall be used in accordance withEN ISO 13341.SIST EN 1802:2002



EN 1802:2002 (E)11The torque applied shall take into consideration the size and form of the threads, the material of the valve, and thetype of sealing material used according to the manufacturer's recommendations. Where the use oflubricants/sealing material is permitted, only those approved for the gas service shall be used, taking particular carefor oxygen service in accordance with EN ISO 11114-2.12.3 Check on cylinder tareThis requirement shall only apply to cylinders for liquefied gases. The tare of the cylinders shall be obtained byweighing on a machine regularly checked for accuracy. The capacity of the weighing machine shall be suitable forthe tare weight of the cylinders.The tare shall include the mass of the cylinder, valve(s) and all permanent fittings. If the tare of the cylinder differsfrom the stamped tare by more than the value shown in Table 1 and is not due to reasons of damage, the originaltare shall be cancelled and the correct tare shall be marked in a permanent and legible fashion in accordance withEN 1089-1.Table 1 — Maximum allowable deviation incylinder tare weightCylinder watercapacity (V)Maximum allowabledeviation in tareweightlg0,5
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



EN 1802:2002 (E)12-
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
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