Cylinder Requalification Student Manual
Cylinder Requalification Student Manual
Cylinder Requalification
2017 Edition
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CYLINDER REQUALIFICATION
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CONTENTS: CYLINDER REQUALIFICATION
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CYLINDER REQUALIFICATION
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LESSON 1: INTRODUCTION TO CYLINDER
REQUALIFICATION
P
ropane cylinders provide a portable and convenient way for residential, recreational, and
commercial users of propane to fuel equipment and appliances. Propane cylinders can be
found at many locations, including hardware stores, professional landscape companies,
campgrounds, rental equipment companies, and gas stations.
In order to ensure your safety and the safety of your customers, propane cylinders must be inspected prior to
each time they are filled. One step in the pre-fill inspection identifies cylinders that are due for requalification
before they can be returned to service.
This manual provides information about the properties and characteristics of propane, the different types of
DOT cylinders requiring periodic requalification, and in depth procedures for requalifying DOT cylinders using the
external visual inspection method.
•• List the process steps for DOT cylinder requalification by visual inspection.
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CYLINDER REQUALIFICATION
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LESSON 2: PROPERTIES AND CHARACTERISTICS OF
PROPANE
INTRODUCTION
T
he safe handling of propane involves knowing its properties and characteristics and
being aware of safety procedures. A Safety Data Sheet, or SDS, is available from propane
suppliers or distributors and must be available and accessible to all employees at the
workplace. The SDS provides important information on propane, including physical
properties, health effects, first aid, safety precautions, and personal protective equipment.
Propane is stored as both a liquid and a vapor. As propane
liquid turns to vapor, it expands 270 times. Because of the large
expansion rate, a liquid propane leak can be more hazardous
than a propane vapor leak.
Propane is a fuel; it will ignite and burn under the right conditions. Three ingredients are needed to start and
sustain combustion: propane, oxygen, and an ignition source. In order to minimize possible ignition sources
that could lead to combustion, customers should be restricted from the immediate area around the cylinder
requalification area.
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CYLINDER REQUALIFICATION
DETECTING PROPANE
A strong, unpleasant-smelling chemical is added to propane so
you can detect it. The chemical added to propane makes it smell
like rotten eggs, a skunk’s spray, or a dead animal. You should
respond immediately to even a faint odor of propane.
Sources of Ignition
You should be aware of any potential ignition sources any time you are handling propane cylinders. Some
examples include: a person smoking, open flames, internal combustion engines, and static electricity. Make
sure you eliminate any potential ignition sources before handling propane cylinders.
In the right conditions, a source of ignition such as a static discharge or spark may cause the ignition of
some fuels, including gasoline and propane. For more information on controlling static electricity, visit
propanecouncil.org.
Everyone in the building, or area affected by the emergency, should evacuate immediately to a safe distance.
Do not re-enter the area.
After you are at a safe distance from the affected area, call 911 or your local fire department.
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LESSON 3: DOT CYLINDERS
INTRODUCTION
A
n important part of a cylinder requalifier's job is being able to recognize various types of
propane cylinders and understanding their markings. This helps to ensure that cylinders
due for requalification are identified and removed from service until the requalification
process is complete.
Most propane cylinders in service today are manufactured according to Department of Transportation (DOT)
specifications and are commonly referred to as “DOT cylinders.”
Small, portable cylinders are filled at various locations and are used with hand torches, plumbers’ pots, gas
lanterns, camp stoves, barbecue grills, and on many recreational vehicles.
Larger cylinders are typically filled at a facility and delivered to industrial, commercial, or residential customers.
Every aluminum or steel cylinder has a foot ring. It is used to protect the
bottom of the cylinder body from damage and also functions as a support
stand or base.
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CYLINDER REQUALIFICATION
These include:
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LESSON 3: DOT CYLINDERS
CYLINDER MARKINGS
Markings are required by DOT and are the ID card for
the cylinder. Markings must be legible and clearly and
permanently marked on the collar or cylinder body.
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DISCOVERY – PORTABLE CYLINDER MARKINGS
CYLINDER REQUALIFICATION
LEARNING ACTIVITY
8
DISCOVERY – EXCHANGE CYLINDER MARKINGS
LESSON 3: DOT CYLINDERS
LEARNING ACTIVITY
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CYLINDER REQUALIFICATION
•• The letter “S” following the date indicates the cylinder must be
requalified within seven years of the marked date.
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LESSON 3: DOT CYLINDERS
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CYLINDER REQUALIFICATION
CYLINDER LABELING
DOT and OSHA require specific labeling for all cylinders.
Cylinders used to transport propane must be clearly and
durably marked with the proper shipping name and hazard
class. Cylinders used in industrial applications must have
additional warning information.
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LESSON 4: DOT REQUALIFICATION REQUIREMENTS
INTRODUCTION
T
his lesson considers the requirements for the Requalification
requalification of propane cylinders under the jurisdiction The process by which a DOT cylinder
of the DOT. must be taken out of service,
retested, and found to be suitable for
continued service on or before the
required date. Most companies that
are authorized to requalify cylinders
do so by external visual inspection.
DOT CYLINDERS
According to DOT regulations, cylinders used to transport hazardous
materials in commerce are DOT specification containers, which are:
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CYLINDER REQUALIFICATION
REQUALIFICATION SCHEDULE
For cylinder types 4B, 4BA, 4BW, and 4E, specifications
state that cylinders filled and transported over public Volumetric Expansion Test using
roads to customer locations be requalified within 12 the Water Jacket Method
years after the date of manufacture, and:
Cylinder is pressurized to two
•• Every 12 years thereafter, if requalified by a times the designed working
volumetric expansion test using the water pressure of the cylinder. During
jacket method. A date without a letter the test, a metal jacket filled with
indicates the cylinder was subjected to a water water surrounds the cylinder. The
jacket volumetric expansion test at its last jacket is used to measure the
requalification. amount of permanent expansion
of the cylinder body when under
– or – pressure. Once this is completed,
a rigorous, visual inspection of
•• Every seven years thereafter if the internal the cylinder is performed.
hydrostatic pressure test requalification
method is used. A date followed by the letter
“S” indicates an internal hydrostatic test was
performed at the last requalification.
– or – Internal Hydrostatic Test
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LESSON 4: DOT REQUALIFICATION REQUIREMENTS
REQUALIFICATION PERSONNEL
Persons who requalify cylinders using the external
visual inspection method must:
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CYLINDER REQUALIFICATION
Every facility that requalifies DOT cylinders by visual inspection must be approved by the Associate
Administrator for Hazardous Materials Safety.
The application process consists of filing a new application, or renewal application every five years after the
initial approval. The application requires:
•• Training documentation/certification records for each employee performing external visual inspections.
For a current copy of the application/renewal form, see Resources. The current form is also available online at
http://www.phmsa.dot.gov/staticfiles/PHMSA/DownloadableFiles/Files/New_Visual_Application_2015.pdf, or by
calling 202-366-4535.
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LESSON 4: DOT REQUALIFICATION REQUIREMENTS
Requalification
Condemn Repair
A determination that a cylinder The procedure for correction of a
is unsafe for the continued rejected cylinder that may involve
transportation of hazardous welding. Replacing a cylinder
materials in commerce and valve or fitting is not considered
that the cylinder may not be a cylinder repair under the
restored by repairing, rebuilding, regulations.
requalification, or any other
procedure.
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CYLINDER REQUALIFICATION
Requalification Identification
Number (RIN)
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LESSON 4: DOT REQUALIFICATION REQUIREMENTS
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CYLINDER REQUALIFICATION
RECORDS RETENTION
Requalification records must be maintained at the
facility until either:
– or –
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LESSON 4: DOT REQUALIFICATION REQUIREMENTS
Your boss has asked you to help him set up the cylinder requalification process at a new facility. From the list
below, identify the DOT requirements from which you based your recommendations.
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CYLINDER REQUALIFICATION
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LESSON 5: REQUALIFICATION PROCESS
OVERVIEW
T
he external visual inspection procedure for requalification involves an examination of the
outside of the cylinder body and all attachments. The cylinder body, data markings, neck
and foot rings, collars, etc., are all inspected for damage from abuse, fire, corrosion, dents,
bulges and gouges. The results of each step of the procedure must be documented on records
per DOT regulations.
Another part of the inspection procedure includes weighing the
empty cylinder and performing a leak test of the cylinder and
fittings. This is done by charging the cylinder with propane vapor
and using a suitable leak detector solution or device.
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CYLINDER REQUALIFICATION
OO
RR
Gather forms Neck or valve Reject (RM)
damage
OO
RR
Empty and Scrap or
Attachment
clean cylinder condemn (SC)
damage
Dents
Cuts, gouges,
digs
Corrosion
Tare weight
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LESSON 5: REQUALIFICATION PROCESS OVERVIEW
OO
RR
Gather forms Neck or valve Reject (RM)
damage
OO
Empty and
Attachment RR
Scrap or
clean cylinder condemn (SC)
damage
Dents
Cuts, gouges,
digs
Corrosion
Tare weight
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CYLINDER REQUALIFICATION
Dents
Cuts, gouges,
digs
Corrosion
Tare weight
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LESSON 5: REQUALIFICATION PROCESS OVERVIEW
OO
RR
Gather forms Neck or valve Reject (RM)
damage
OO
RR
Empty and Scrap or
Attachment
clean cylinder condemn (SC)
damage
Dents
Cuts, gouges,
digs
Corrosion
Tare weight
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CYLINDER REQUALIFICATION
•• Returned to service.
•• Marked appropriately.
Regardless of the cylinder disposition, the inspection report must be completed fully for each cylinder.
Dents
Cuts, gouges,
digs
Corrosion
Tare weight
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LESSON 5: REQUALIFICATION PROCESS OVERVIEW
Match the cylinder requalification task with the appropriate part of the cylinder requalification process. Some
answers are used more than once.
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CYLINDER REQUALIFICATION
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LESSON 6: PREPARE FOR REQUALIFICATION
INTRODUCTION
T
his lesson looks at the detailed process for preparing a cylinder for requalification. A
decision chart includes the questions you must ask yourself while preparing a cylinder for
requalification. To view the entire decision chart for the DOT cylinder requalification by
visual inspection process, see Resources.
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CYLINDER REQUALIFICATION
32
LESSON 6: PREPARE FOR REQUALIFICATION
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CYLINDER REQUALIFICATION
34
LESSON 6: PREPARE FOR REQUALIFICATION
The following requalification dates are found on cylinders at your facility. All the cylinders are types 4B, 4BA,
4BW, or 4E. Using the chart below, check when the next requalification is required in each case.
1. 10 14
¨ 5 years
¨ 7 years
¨ 12 years
2. 07 16E
¨ 5 years
¨ 7 years
¨ 12 years
3. 05 12S
¨ 5 years
¨ 7 years
¨ 12 years
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CYLINDER REQUALIFICATION
While each company's Visual Inspection Report form may look different, it
will include space for you to record the following items:
•• Date of inspection.
•• Cylinder disposition:
–– Rejected/Removed from
Service. Hold for repairs is
indicated on the form with R or
RM. The reason for the rejection must also be documented.
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LESSON 6: PREPARE FOR REQUALIFICATION
EVACUATE A CYLINDER
Identify which cylinders need to be evacuated. If you
have the appropriate equipment to evacuate cylinders
and you are trained to do so, evacuate the cylinders as
required.
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CYLINDER REQUALIFICATION
Receiving
WARNING: Be careful not to overfill ASME Tank
Elevated Dock or Platform
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LESSON 6: PREPARE FOR REQUALIFICATION
•• A scavenging tank.
•• A storage tank.
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CYLINDER REQUALIFICATION
1. Open the vapor lines connecting the compressor to the scavenger tank and the storage tank. Remember to
leave the liquid line between the scavenger tank and the storage tank closed.
The compressor draws vapor out of the scavenging tank and forces it into the bulk storage tank. As a result,
the pressure in the scavenging tank is reduced. The pressure difference between the scavenging tank and the
evacuating cylinder pulls the liquid from the cylinder into the scavenging tank.
When the scavenging tank reaches the maximum filling level, the propane must be transferred to the storage
tank. To accomplish this, do the following:
3. Reverse the vapor line connections or change the position of the four-way valve on the compressor so the
compressor pulls vapor from the storage tank.
The compressor pulls vapor out of the bulk storage tank and forces it into the scavenging tank. The higher
pressure now in the scavenging tank forces the liquid into the bulk storage tank. This empties the scavenging
tank. It is ready to continue evacuating the cylinder or to evacuate other containers.
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LESSON 6: PREPARE FOR REQUALIFICATION
•• Dip tube.
Liquid service cylinders are emptied easily because the valving is designed for liquid withdrawal.
1. With vapor hoses already connected to the compressor, connect a propane liquid hose with a shutoff valve on
each end between the cylinder and scavenging tank.
2. Turn on the compressor. The higher pressure in the cylinder forces liquid to flow up the dip tube in the cylinder
and into the scavenging tank.
3. As the liquid level in the cylinder reaches the bottom of the dip tube, the liquid is no longer removed.
NOTE: When evacuating liquid propane, be careful not to slug the excess flow valve.
This method should be used only if you are confident in the integrity of the container,
for example, it is within its requalification date and has no visible damage, because
this method elevates the pressure in the cylinder.
Dip
Tube
to Compressor
Withdrawel
Point for
Liquid Service
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CYLINDER REQUALIFICATION
Scavenging Tank
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LESSON 6: PREPARE FOR REQUALIFICATION
You are using a compressor system to evacuate the liquid propane from cylinders that need requalification. The
scavenging tank has reached the maximum filling level. You turn the compressor off and close all valves. What
would be the next step to recover what is in the scavenger tank?
Reverse the vapor line connections or change the position of the four-way valve.
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CYLINDER REQUALIFICATION
44
LESSON 6: PREPARE FOR REQUALIFICATION
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CYLINDER REQUALIFICATION
Remove any rust, dirt, or caked paint from the cylinder surface.
Use permanent paint to circle any cuts, gauges, dents, bulges, digs, fire damage, or other problem
areas.
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LESSON 7: PERFORM AN INSPECTION ON A
STEEL CYLINDER
T
his lesson looks at the specific
tasks you must complete during
the visual inspection of a steel
DOT cylinder up for requalification.
It considers the properties of each
type of potential damage you may
find during inspection, as well as
the criteria for both rejection and
condemnation.
The decision chart includes the questions
you must ask yourself while inspecting the
cylinder. To view the entire decision chart
for the DOT cylinder requalification by visual
inspection process, see the foldout chart in
the Resources section of this book.
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CYLINDER REQUALIFICATION
FIRE DAMAGE
The first question you must ask yourself is whether
the cylinder has sustained fire damage. Exposure to
fire can seriously weaken a cylinder by changing the
metallurgical structure or the strength properties of
the metal. Regulations state that a cylinder subjected
to fire shall not be placed in service until it has been
reconditioned properly in accordance with 49 CFR.
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LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER
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CYLINDER REQUALIFICATION
50
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER
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CYLINDER REQUALIFICATION
You are requalifying a cylinder and are at the point of inspecting for fire damage. Check the items in the list
below that may indicate there is fire damage.
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LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER
CYLINDER DISTORTION
If the cylinder shows no evidence of fire damage,
check to see if the cylinder is distorted.
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CYLINDER REQUALIFICATION
MEASURE DISTORTIONS
Cylinders that have visible distortions or bulges must
be removed from service. If you are unsure if a bulge is 2. Measure and record the distance from the center of
within acceptable limits, consult with your supervisor the service valve opening at the neck to the line or
or contact your fuel supplier. waist seam. Repeat this step three times, moving
the tape each time so that the tape strikes the line
Follow these steps to determine if bulges are within or waist seam at different points.
acceptable limits:
54
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER
55”
55.1”
16.4”
16” 55”
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CYLINDER REQUALIFICATION
56
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER
57
CYLINDER REQUALIFICATION
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LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER
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CYLINDER REQUALIFICATION
60
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER
The term “neck” refers to the _______________ opening in cylinders that contain only one top opening or service
end.
Service valve.
Filler valve.
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CYLINDER REQUALIFICATION
62
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER
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CYLINDER REQUALIFICATION
64
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER
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CYLINDER REQUALIFICATION
66
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER
DENTS
If the cylinder attachments have passed inspection,
check to see if the cylinder has any significant dents.
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CYLINDER REQUALIFICATION
•• Are not on a weld where the depth of the dent is greater than
1/10th (10%) of the greatest dimension of the dent, or
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LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER
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LEARNING ACTIVITY: REQUALIFICATION OF DOT CYLINDERS
CYLINDER REQUALIFICATION
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LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER
•• corrosion
To determine whether a cut, gouge, dig, or area of corrosion is within tolerance, calculations based on the
minimum allowable design thickness shown in this table are used.
NOTE: The values shown in this table are the minimum allowable thicknesses according to design specifications.
A specific manufacturer may produce cylinders with thicknesses higher than the minimum.
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CYLINDER REQUALIFICATION
Remaining
Wall Thickness
72
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER
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CYLINDER REQUALIFICATION
74
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER
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CYLINDER REQUALIFICATION
Select the tools required to measure damage from cuts, gouges, or digs in a cylinder. Check all that apply.
Carpenter’s rule.
Rubber mallet.
Level.
T-square.
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LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER
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CYLINDER REQUALIFICATION
NOTE: Be aware that when there is a cluster of •• Repeat until all areas of general corrosion are
isolated pitting in an area, figure the average checked.
depth of the isolated pitting to be twice the
depth of any general corrosion.
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LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER
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CYLINDER REQUALIFICATION
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LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER
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CYLINDER REQUALIFICATION
Identify the type of corrosion that is NOT defined in the cylinder requalification procedure.
General corrosion.
Weld corrosion.
Isolated pitting.
Line corrosion.
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LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER
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CYLINDER REQUALIFICATION
84
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER
A cylinder that has lost more than ________% of its marked tare weight should be condemned.
15
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CYLINDER REQUALIFICATION
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LESSON 8: TEST FOR LEAKS
A
fter a cylinder has passed the visual 3: Leak Test
inspection portion of the requalification
process, the cylinder must be tested Leaks in cylinder
NO
Mark report OK.
after charging with Continue to Step 4: Process
for leaks before the cylinder can be propane vapor and
requalified. using suitable leak
detector solution?
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CYLINDER REQUALIFICATION
LEAK TEST
If the cylinder you are working with has passed the
Inspect portion of the cylinder requalification process,
you are ready to test the empty cylinder for leaks.
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LESSON 8: TEST FOR LEAKS
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CYLINDER REQUALIFICATION
90
LESSON 8: TEST FOR LEAKS
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CYLINDER REQUALIFICATION
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LESSON 9: PROCESS THE CYLINDER
INTRODUCTION
N
ow that you have completed
the first three steps of the
requalification process (Prepare,
Inspect, and Leak Test), and
marked the Visual Inspection
Report form with OK, RM, or SC
based on the cylinder disposition,
it is time to mark the cylinder itself
based on the inspection results and
make sure your documentation is
complete. In this lesson, we look
at the tasks involved to process
inspected cylinders and complete
the requalification inspection
requirements.
The decision chart includes the questions
you must ask yourself while processing
an inspected cylinder. To view the entire
decision chart for the DOT cylinder
requalification by visual inspection process,
see Resources.
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CYLINDER REQUALIFICATION
The marking for cylinders that have passed inspection must include the following information:
•• The month and year of the requalification. For example, 5/10 indicates May 2010.
•• The letter E after the requalification date to indicate the cylinder passed all external visual inspection
requalification requirements.
Before returning the requalified cylinder to service, verify the cylinder is marked appropriately by one of the
methods outlined in regulations:
•• Stamping.
•• Scribing.
•• Engraving.
Refer to your company policy or propane supplier for more information on the marking method to use.
You should also verify that cylinder inspection results have been fully documented on the Visual Inspection
Report form before beginning another cylinder inspection.
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LESSON 9: PROCESS THE CYLINDER
When a cylinder is rejected/removed from service (RM) at any step in the requalification process, the cylinder
must be set aside, repaired and requalified before it is placed back into service.
1. Make sure that the appropriate column on the inspection form is marked RM.
2. Note the cause of the rejection in the Comment section of the inspection form.
3. Permanently mark with paint or a waterproof marker the point or part of the cylinder that failed the inspection
and caused the rejection.
NOTE: Some cylinders may be repaired on site and some must be sent to a DOT-approved test-station facility
for repair. Check with your supervisor or plant manager for the destination of the cylinder in question.
You should also verify that cylinder inspection results have been fully documented on the Visual Inspection
Report form before beginning another cylinder inspection.
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CYLINDER REQUALIFICATION
1. Make sure the appropriate column on the inspection form is marked with the letters SC.
2. If the cylinder belongs to a customer or someone other than the company, notify the cylinder owner in writing
that the cylinder is condemned and cannot be filled with hazardous material.
3. With the approval of the cylinder owner, stamp a series of Xs over the DOT specification number and pressure
stamping; or, stamp CONDEMNED on the shoulder, top head, or neck using a steel stamp.
As an alternative to condemnation stampings, DOT regulations allow the requalifier, at the direction of the
owner, to render the cylinder incapable of holding pressure.
You should also verify that cylinder inspection results have been fully documented on the Visual Inspection
Report form, before beginning another cylinder inspection.
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LESSON 9: PROCESS THE CYLINDER
If, after inspection, a cylinder needs to be rejected and sent for repairs before returning it to service, which of
the following items is NOT part of the process to reject the cylinder?
Circle the appropriate column in the inspection form that is marked R or RM.
Send the cylinder to a DOT-approved test-station facility for repair. Check with your supervisor or plant
manager for the exact location and method of shipment.
Permanently mark with paint or a waterproof marker at the point or part of the cylinder that failed the
inspection.
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CYLINDER REQUALIFICATION
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LESSON 10: SPECIAL REQUALIFICATION CONSIDERATIONS
FOR CERTAIN CYLINDER MATERIALS AND TYPES
INTRODUCTION
T
he cylinder requalification procedures
presented in the last several lessons
focused on requalifying steel DOT
cylinders. In this lesson, we will consider
the variations in the requalification procedure
for DOT cylinders made of different materials
and for those cylinders used for specific
purposes.
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CYLINDER REQUALIFICATION
100
LESSON10:SPECIALREQUALIFICATIONCONSIDERATIONSFORCERTAINCYLINDERMATERIALSANDTYPES
Dents away from welds Reject a steel cylinder if the depth of the dent not on Condemn an aluminum cylinder when the depth
a weld is greater than 1/10 of the greatest dimen- of a dent exceeds 1/10 of the average diameter
sion of the dent. of the dent.
Cuts, gouges, digs 1. When the original cylinder wall thickness is known, 1. When the original wall thickness is known,
condemn a steel cylinder if the original wall condemn an aluminum cylinder if the original
thickness minus the depth of the defect is less than wall thickness minus the depth of the defect is
1/2 of the MADT. less than 75% of the original wall thickness.
2. When the original wall thickness is unknown, 2. When the original wall thickness is unknown,
condemn a steel cylinder when the defect exceeds condemn the aluminum cylinder if the defect
1/2 of the MADT. exceeds 25% of the minimum designed wall
thickness.
3. Condemn steel cylinders at 1/2 of the limit set
whenever the length of the defect is 3 inches or
more.
Neck cracks Reject and repair, or condemn a steel cylinder with a Condemn an aluminum cylinder with a neck
neck crack. crack.
**According to DOT specifications, DOT 4E aluminum cylinders must have a minimum wall thickness of at least
0.140 inches. However, the actual minimum allowable wall thickness of DOT 4E aluminum cylinders is based
on the cylinder service pressure, diameter, material strength, and process capability. To determine the precise
minimum allowable wall thickness of the cylinder design, contact the cylinder manufacturer.
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LESSON10:SPECIALREQUALIFICATIONCONSIDERATIONSFORCERTAINCYLINDERMATERIALSANDTYPES
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LESSON10:SPECIALREQUALIFICATIONCONSIDERATIONSFORCERTAINCYLINDERMATERIALSANDTYPES
NFPA 58 allows composite cylinders to be used for propane service under a special permit issued by DOT.
True
False
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LESSON 11: CYLINDER REQUALIFICATION SUMMARY
INTRODUCTION
In this course, you learned how to:
•• Mark the cylinder appropriately after completing the inspection and all documentation.
You also learned about special requirements that apply to aluminum, composite, stationary, forklift, and small
engine cylinders.
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This included:
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LESSON 11: CYLINDER REQUALIFICATION SUMMARY
You then looked at the details involved in performing each step of the requalification process as shown in
the chart below. You learned how to determine if damage to a cylinder is within acceptable limits, and when
a cylinder should be rejected for repair, or condemned. The training materials reviewed specifically covered
requirements for steel DOT cylinders.
OO
RR
Gather forms Neck or valve Reject (RM)
damage
OO
RR
Empty and Scrap or
Attachment
clean cylinder condemn (SC)
damage
Dents
Cuts, gouges,
digs
Corrosion
Tare weight
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1: Prepare 2: Inspect 3: Leak Test
YES
Reject cylinder, mark report RM.
Based on Obtain Visual Fire Can/will cylinder be requalified* NO Continue to Step 4: Process Leaks in cylinder Mark report OK.
YES NO
manufacture / YES Inspection damage? by volumetric expansion test after charging with Continue to Step 4: Process
Requalification date: Report form (water jacket method)? Condemn cylinder, mark report SC. propane vapor and
NO
Is cylinder due for Continue to Step 4: Process using suitable leak
requalification? detector solution?
DOT CYLINDER REQUALIFICATION BY VISUAL INSPECTION CHART
NO
threaded opening? approval, mark cylinder as
* Refer to your company policy. Some marketers may send eligible cylinders for repair condemned or render it
and requalification while others may condemn cylinders in the same condition. incapable of holding pressure
Continue to ** CGA 6 allows for cylinders that have lost 5-10% of their marked tare weight to be
requalified by water jacker or direct expansion testing. However, many marketers
Step 3: Leak Test
routinely condemn cylinders that have lost more than 5% of their marked tare weight.
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LESSON 11: CYLINDER REQUALIFICATION SUMMARY
•• Reject for repairs/remove from service – R or RM. Include the reason for rejection in the Comments
section of the inspection report.
•• Scrapped/condemned – SC.
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MARKING CYLINDERS
You learned how to mark the cylinders based on their
disposition after inspection. Cylinders should be
marked by:
•• Stamping.
•• Scribing.
•• Engraving.
or
or
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LESSON 11: CYLINDER REQUALIFICATION SUMMARY
•• Aluminum cylinders.
•• Composite cylinders.
•• Stationary cylinders.
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COURSE QUIZ
Directions: Let’s take a moment to check how well you understand the information presented in this course.
Select the appropriate answer for each of the following questions.
_________________________________________________________________________________________
1. In the event of a propane emergency, you should?
_________________________________________________________________________________________
2. Which of the following are NOT approved testing methods for DOT cylinder requalification? Select all that
apply:
____________________________________________________________________________________________
3. Personnel responsible for the requalification of DOT cylinders by external visual inspection must be thoroughly
familiar with ______________ that apply to cylinder requalification. Select all that apply.
a. OSHA guidelines
b. ASME standards
c. CGA standards
d. EPA regulations
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____________________________________________________________________________________________
4. In which case is it NOT acceptable to use ditto marks on a cylinder requalification inspection form to indicate
repeated information from the proceeding entry?
a. Date.
b. Manufacturer’s name or symbol.
c. Cylinder disposition.
d. Person handling requalification.
____________________________________________________________________________________________
5. Why is weighing the cylinder an important part of the cylinder requalification process?
a. To make sure the cylinder is not marked with an incorrect tare weight.
b. To make sure to the cylinder has not lost more than 5% of its marked tare weight.
c. To make sure the cylinder has not gained more than 5% of its marked tare weight.
d. To make sure the cylinder is empty for inspection.
____________________________________________________________________________________________
6. To prepare for a DOT cylinder requalification inspection you need to perform all of the tasks below except:
____________________________________________________________________________________________
7. If the last requalification date on a cylinder is 03/15 E, when is the cylinder next due to be requalified?
a. March of 2022.
b. March of 2027.
c. March of 2020.
d. March of 2021.
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COURSE QUIZ
________________________________________________________________________________________
8. Match each picture with the type of damage it shows.
______ Dent
A.
B.
C.
______ Corrosion
D.
E.
F.
G.
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____________________________________________________________________________________________
9. Which of the following is NOT specifically included in the requalification inspection of a DOT cylinder?
a. Cuts.
b. Gouges.
c. Scuffs.
d. Dents.
____________________________________________________________________________________________
10. The leak test step in the requalification process should be performed using:
a. Propane liquid.
b. Propane vapor.
c. Water.
d. Compressed air.
____________________________________________________________________________________________
11. CGA C-6 stipulates that if the weight loss is between 90 and 95%, the cylinder can be requalified by water
jacket or direct expansion testing. True or False?
a. True.
b. False.
____________________________________________________________________________________________
12. A successfully requalified cylinder should be marked as such on the:
a. Foot ring.
b. Collar.
c. Bottom of the cylinder.
d. Service valve.
____________________________________________________________________________________________
13. A customer brings in a cylinder that he/she own for requalification and filling. The result of the inspection is
SC. What do you need to do next?
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COURSE QUIZ
____________________________________________________________________________________________
14. Aluminum cylinders that have been exposed to fire must be:
____________________________________________________________________________________________
15. DOT cylinders in stationary service should be requalified 12 years from the date of manufacture and
every 5 years thereafter with the exception of the requirement of:
a. Leak testing.
b. Foot ring inspection.
c. Tare weight verification.
d. Attachments.
____________________________________________________________________________________________
16. Engine fuel cylinders used on industrial (and forklift) trucks are not required to be equipped with:
____________________________________________________________________________________________
17. Isolated pitting or line corrosion could be missed on visual inspection if you don’t ________________.
a. Remove all dirt, paint, and other rust from the cylinder before inspection.
b. Inspect the interior of the cylinder.
c. Remove all valves.
d. Empty the cylinder.
____________________________________________________________________________________________
18. You are inspecting a 100 lb 4B-240 cylinder that has an area of line corrosion measuring 5 inches long with a
depth of 0.034 inches. Using the LP-Gas Cylinder Damage Limits chart, can the cylinder be requalified?
a. Yes.
b. No.
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19. You are inspecting a cylinder that has a dent on a weld. The dent depth is 0.29 inches. What should you do
with the cylinder?
____________________________________________________________________________________________
20. How do you determine the minimum allowable tare weight for a specific cylinder to be requalified?
____________________________________________________________________________________________
21. There must be at least ______ continuous full threads for tapered cylinder neck threads to pass requalification
inspection.
a. Six
b. Five
c. Three
d. Four
____________________________________________________________________________________________
22. If a leak is found at _______________, you may reseal it and test for leaks again.
____________________________________________________________________________________________
23. If a cylinder is rejected during a requalification inspection and marked RM on the report, you should do all
except:
a. Mark the area of the cylinder that failed inspection with paint or waterproof marker.
b. Stamp XXXX over the cylinder DOT specification number.
c. Note the cause of the rejection in the comments section of the report.
d. Repair the cylinder or send the cylinder out for repairs.
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COURSE QUIZ
____________________________________________________________________________________________
24. When a cylinder in stationary service is inspected and requalified at the customer site, you must include the
RIN in the requalification stamp.
a. True.
b. False.
____________________________________________________________________________________________
25. Small engine cylinders are very similar to _________ cylinders except that they typically have left-hand threads
on male and female safety couplers.
a. BBQ
b. ASME
c. Stationary
d. Forklift
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CERTIFICATE OF TRAINING
Propane Education & Research Council (PERC)
completed the PERC Training Course for Cylinder Requalification. I understood the training, I have had an
opportunity to ask questions, and all of my questions were properly answered. I have had hands-on practice to
requalify cylinders, and can effectively perform requalification.
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CHECK YOUR WORK
Lesson 4: Check for Understanding – DOT Lesson 6: Check for Understanding – Prepare for
Requalification Requirements Requalification
The plant manager asked you to help him set up the The following requalification dates are found on
cylinder requalification process at a new facility. From cylinders at your facility. All the cylinders are types 4B,
the list below, identify the DOT requirements that you 4BA, 4BW, or 4E. Using the chart below, select when
based your recommendations on. the next requalification is required in each case.
a. DOT Requalification Schedule, c. Requalification reports 1. 10 14 12 years
and record retention specifications, e. External visual
inspection personnel qualifications. 2. 07 16E 5 years
3. 05 12S 7 years
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CYLINDER REQUALIFICATION
Lesson 6: Check for Understanding – Prepare for Lesson 7: Check for Understanding – Perform an
Requalification Inspection on a Steel Cylinder
When preparing to perform a requalification Select the tools required to measure damage from
inspection, you must ____________________? cuts, gouges or digs in a cylinder. Select all that apply.
a. Remove any rust, dirt, or caked paint from the cylinder a. carpenter’s rule, d. industrial depth gauge.
surface, c. Obtain a visual inpsection form,
d. Determine the requalification date, f. Empty the cylinder of Lesson 7: Check for Understanding – Perform an
any liquid propane. Inspection on a Steel Cylinder
Identify the type of corrosion that is NOT defined in the
cylinder requalification procedure.
Lesson 7: Check for Understanding – Perform an
Inspection on a Steel Cylinder b. Weld corrosion.
2. Yes.
3. No.
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CONTENTS
Pressure Measurements
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PRESSURE MEASUREMENTS
Pressure measurements can be expressed using different units of measure. In the US, the most common units
are pounds per square inch, or psi. In addition, pressure can be measured on either of two different scales, each
using a different zero reference point. These two measurement scales are called gauge pressure and absolute
pressure.
The surrounding air pressure, commonly called barometric pressure, is defined as the force exerted on a 1 inch
square piece of ground by a column of air reaching to the top of the earth’s atmosphere. Pressure relative to
atmospheric pressure is called gauge pressure. Gauge pressure is expressed as psig (g for gauge), and uses
atmospheric pressure as a zero reference point.
In the US, most industrial pressure measurements are expressed in psig. A pressure greater than atmospheric
pressure is expressed as a positive number. A pressure less than atmospheric pressure, a condition known as a
vacuum, is expressed as a negative number.
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CYLINDER REQUALIFICATION
•• Improper Purging: Check to see if the cylinder is new or has been open to the atmosphere recently and, if
so, ensure it was properly purged.
•• Overfilling: Check the liquid level in the cylinder by opening the fixed maximum liquid level gauge and
checking for the presence of liquid, or by weighing the container on an accurate scale. If you think that
the cylinder is overfilled, immediately remove it from service.
•• Presence of Hot Gas: Hot gas is more than normal amounts of lighter hydrocarbons such as propylene,
ethane, and methane in the container causing higher pressure. If improper purging or overfilling was not
the problem, there is a good chance it is due to hot gas. Therefore, the container must be flared using
suitable flaring equipment.
•• Incorrect application - relief valve that is not correct for the intended use
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Before installing a new valve stem, seal, or disc (soft seat), make certain that container is depressurized , the
operator stem and handwheel are unscrewed and the valve is fully open. If this is not done, the valve disc is
easily damaged when the packing nut is tightened.
Never over-tighten the packing nut when reassembling any service valve. Over-tightening damages the packing
seal. Check the manufacturer’s instructions for the correct tightening specifications.
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Company Name: _______________________________________________________________
(If you are a company that is doing business as (dba), use the following format, corporate name dba company name)
I certify that this facility will operate in compliance with all applicable requirements of the Hazardous Materials Regulations,
including the requirements of 49 CFR Part 180.209(g) relating to the requalification of cylinders by the visual inspection
method. I further certify that the individuals performing external visual inspections at the facility address referenced above
have been trained and have received the appropriate information, as applicable, contained in CGA Pamphlet C-6 (Standards
for Visual Inspection of Steel Compressed Cylinders) and C-6.3 (Guidelines for Visual Inspection and Requalification of Low
Pressure Aluminum Compressed Cylinders).
NOTE: Please include training documents/certification, as part of your complete approval application, for each
employee performing external visual inspection at the reference facility address in accordance with the training
requirements of 49 CFR Part 172.704.
_____________________________________________________________________________________________
Name (Print) Signature Date
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PREPRESS:
INSERT 11 X 17 FOLDOUT HERE -
SEE FILE: Big_Chart_24x18.pdf or Big Chart
36x24.pdf
Location folder: Dropbox/Cylinder Requalifica-
tion Course/Flow Charts. There are also two Illus-
trator files in the same folder.
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