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Cylinder Requalification Student Manual

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88 views138 pages

Cylinder Requalification Student Manual

Uploaded by

zulqanine.hbs
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Cylinder Requalification

Cylinder Requalification

2017 Edition

1
CYLINDER REQUALIFICATION

NOTICE AND DISCLAIMER CONCERNING LIABILITY

The Propane Education & Research Council (PERC) is a non-profit 501(c)6 PERC, NPGA, GPA, and the industry members make no warranty or guaranty
trade organization authorized by the Propane Education and Research Act of as to the accuracy or completeness of any information published in this
1996 (PERA), Public Law 104-284. PERC was created to enhance consumer document.
and employee safety and training, to provide for research and development Text and code references found in this document are based on the 2017
of clean and efficient propane utilization equipment, and to inform and edition of NFPA 58: Liquefied Petroleum Gas Code. The procedures and
educate the public about safety and other issues associated with the use of information in this document are intended to implement the standards set
propane.” forth in the documents referenced with capabilities of the personnel and
PERC is governed by a 21-member Board of Directors appointed by the equipment available. It does not create new standards or criteria for
National Propane Gas Association (NPGA) and the Gas Processors compliance. The order of steps in any procedure may or may not be of
Association (GPA). PERC program beneficiaries include propane retail importance. This material is not sold nor is it a product of any consulting or
marketers, producers, transporters, and agricultural cooperatives, as well as engineering activity.
representatives of allied service and supply industries (the industry Users of this document should consult the law of their individual
members). jurisdictions for codes, standards, and legal requirements applicable to
The recommendations, standards, or recommended practices, as reflected them. This document is not intended nor should it be construed to (1) set
in this document, were developed by independent consultants retained by forth policies or procedures that are the general custom or practice in the
PERC. While PERC administers the process of obtaining the information, it propane industry; (2) to establish the legal standards of care owed by
does not independently test or verify the accuracy of the information or propane distributors to their customers; or (3) to prevent the user from using
methods used to collect the data that supports the conclusions or different methods to implement applicable codes, standards, or legal
recommendations reflected in this document. PERC, NPGA, GPA, and the requirements.
industry members disclaim any and all liability for any personal injury,
property damage, business losses, or other damages of any nature By disseminating or publishing this document, PERC is not undertaking to
whatsoever, whether special, indirect, consequential, or compensatory, render any professional or other service to or on behalf of any person or
directly or indirectly resulting from the publication, use, or reliance on this entity. PERC, NPGA, GPA, and the industry members are not undertaking to
document, or any information, apparatus, method, process, or similar item perform any duty owed by any person or entity to any third party. Anyone
disclosed in this document. This disclaimer of liability shall apply even if reading or using this document should rely on his or her own judgment or, as
such loss or damage results, in whole or in part, from any acts or omissions appropriate, should seek the advice of a competent professional in
of or by any negligence on the part of PERC, NPGA, GPA, the industry determining the exercise of reasonable care in any and all circumstances.
members, or any persons who contributed to the development of the
information contained in this document.

Propane Education & Research Council


1140 Connecticut Ave. NW
Suite 1075
Washington, DC 20036

http://www.propanecouncil.org | http://www.propane.com

© PERC 2017 Propane Education & Research Council. All Rights Reserved. No part of this document may be reproduced or transmitted in any form or by any
means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without written permission.

2
CYLIN
REQU
CONTENTS: CYLINDER REQUALIFICATION

LESSON 1: INTRODUCTION TO CYLINDER Inspect the Cylinder 26


REQUALIFICATION 1 Leak Test the Cylinder 27
Course Purpose and Objectives 1 Process the Cylinder 28
Course Resources and References 2 Check for Understanding – Requalification Process
Overview 29
LESSON 2: PROPERTIES AND CHARACTERISTICS OF
PROPANE 3 LESSON 6: PREPARE FOR REQUALIFICATION 31
Introduction 3 Introduction 31
Detecting Propane 4 Prepare for Inspection 32
What You Should Know Before Handling Propane Requalification Periods for DOT Cylinders 33
Cylinders 4 Check for Understanding – Prepare for Requalification 35
Visual Inspection Report 36
LESSON 3: DOT CYLINDERS 5
Empty the Cylinder 37
Introduction 5
Evacuate a Cylinder 37
Common Elements of DOT Cylinders 5
Differential Pressure Evacuation (Gravity Method) 38
Cylinder Markings 7
Compressor System Evacuation 39
Discovery – Portable Cylinder Markings 8
Scavenging System Path 40
Discovery – Exchange Cylinder Markings 9
Compressor System Evacuation on Liquid Service
Cylinder Labeling 12 Cylinders 41
Compressor System Evacuation On Vapor Service
LESSON 4: DOT REQUALIFICATION Cylinders 42
REQUIREMENTS 13
Check For Understanding – Prepare for Requalification 43
Introduction 13
Learning Activity: Evacuating Cylinders 44
DOT Cylinders 13
Clean and Prepare the Cylinder 45
Requalification Schedule 14
Check for Understanding – Prepare for Requalification 46
Requalification Personnel 15
Requalification Records and Reports 17 LESSON 7: PERFORM AN INSPECTION ON A STEEL
Requalification Facility Records 18 CYLINDER 47
Records and Reports 19 Fire Damage 48
Records Retention 20 Rejection Criteria for Fire Exposure 50
Check for Understanding – DOT Requalification Inspect the Cylinder
Requirements 21 Condemnation Criteria For Fire Exposures 51
Check for Understanding – Perform an Inspection on a
LESSON 5: REQUALIFICATION PROCESS OVERVIEW Steel Cylinder 52
23
Cylinder Distortion 53
Requalification Process Overview 24
Measure Distortions 54
Prepare for the Inspection 25

3
CYLINDER REQUALIFICATION

Condemnation Criteria for General Distortion 55 LESSON 9: PROCESS THE CYLINDER 93


Cylinder Leaning 56 Introduction 93
Damage to Valve Openings (Neck) 57 Cylinder Passed Inspection (OK) 94
Requalification Restrictions for Valve Opening Cylinder Rejected/Removed from Service (RM) 95
Damage 59 Cylinder Scrapped/Condemned (SC) 96
Rejection Criteria for Valve Opening Damage 60 Check for Understanding – Process the Cylinder 97
Condemnation Criteria for Valve Opening Damage 60
Check for Understanding – Perform an Inspection on LESSON 10: SPECIAL REQUALIFICATION
a Steel Cylinder 61 CONSIDERATIONS FOR CERTAIN CYLINDER
Damage to Cylinder Attachments 62 MATERIALS AND TYPES 99
Requalification Restrictions for Cylinder Attachment Introduction 99
Damage 64 Requalify Aluminum Cylinders 100
Rejection Criteria for Cylinder Attachment Minimum Allowable Design Thickness for Low
Damage 65 Pressure Cylinders 102
Condemnation Criteria for Cylinder Attachment Requalify Composite Cylinders 103
Damage 65
Requalify Stationary DOT Cylinders 104
Check for Understanding – Perform an Inspection on
a Steel Cylinder 66 Requalify Motor Fuel/Forklift Cylinders 105
Dents 67 Requalify Small Engine Cylinders 106
Damage Limits for Cylinder Dents 68 Check for Understanding – Special Requalification
Considerations for Certain Cylinder Materials and
Condemnation Criteria for Cylinder Dents 69 Types 107
Learning Activity: Requalification of DOT Cylinders 70
Minimum Allowable Design Thickness Table 71 LESSON 11: CYLINDER REQUALIFICATION
Cuts, Gouges, or Digs 72 SUMMARY 109
Damage Limits for Cuts, Gouges, and Digs 73 Introduction 109
Condemnation Criteria for Cylinder Cuts, Gouges, and Requirements for Requalifying DOT Cylinders 110
Digs 75 The Visual Inspection Procedure 111
Check for Understanding – Perform an Inspection on DOT Cylinder Requalification by Visual Inspection
a Steel Cylinder 76 Chart 112
Isolated Pitting, Line Corrosion, and General Disposition of Cylinders after Inspection 113
Corrosion 77 Marking Cylinders 114
Corrosion Damage Limits 79 Special Requirements for Certain Cylinder Types 115
Condemnation Criteria for Cylinder Corrosion 81
Check for Understanding – Perform an Inspection on COURSE QUIZ 117
a Steel Cylinder 82
Tare Weight Check 83 CHECK YOUR WORK 125
Condemnation Criteria for Cylinder Weight 84
RESOURCES 127
Check for Understanding – Perform an Inspection on
a Steel Cylinder 85 Contents 127
Pressure Measurements 128
LESSON 8: TEST FOR LEAKS 87 How to Chase (Clean or Repair) Threads 129
Leak Test 88 Reasons Pressure Relief Valves Open 130
Threaded Opening Leaks 90 Repair Service Valve Considerations 131
Reseal and Retest Valve Threaded Openings 90 Container Marker Requirements 131
Rejection Criteria for Cylinder Leaks 91 Visual Inspection Method Application 132
Condemnation Criteria for Cylinder Leaks 91

4
CYLIN
REQU
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.

COURSE PURPOSE AND OBJECTIVES


The purpose of this course is to provide you with current information, practices, and procedures to safely and
efficiently perform DOT cylinder requalification by visual inspection tasks.

After completing this course, you will be able to:

•• Identify the properties and characteristics of propane.

•• Identify the different types of DOT cylinders.

•• Identify DOT requirements for cylinder requalification.

•• List the process steps for DOT cylinder requalification by visual inspection.

•• Requalify DOT cylinders by visual inspection and document findings.

1
CYLINDER REQUALIFICATION

COURSE RESOURCES AND REFERENCES


Below is an overview of the organizations referenced Code of Federal Regulations (CFR)
throughout this course that develop regulations and
standards for safely handling and storing propane. Any location requalifying DOT cylinders by visual
inspection must comply with several sections of the
National Fire Protection Association (NFPA) Code of Federal Regulations (CFR).

•• 40 CFR includes Environmental Protection


Agency (EPA) regulations that apply if propane is
released to the atmosphere.

Publishes numerous standards for the propane


industry, including:

•• NFPA 58, the Liquefied Petroleum Gas Code,


provides minimum standards for storing,
handling, transporting, and using propane.

•• 29 CFR includes the Occupational Safety and


Compressed Gas Association (CGA) Health Administration (OSHA) regulations that
affect working conditions, safety measures, and
training requirements within a propane plant.

Publishes standards for the propane industry,


•• 49 CFR contains all of the federal rules and
including:
regulations established and maintained by
•• CGA C-6: Standards for visual inspection of steel the Department of Transportation (DOT). It
compressed gas cylinders. applies to commercial motor vehicles and the
transportation of propane in commerce. 49 CFR
•• CGA C-6.3: Guidelines for visual inspection also regulates the construction and inspection of
and requalification of low pressure aluminum propane cylinders.
compressed gas cylinders.

•• Many regulations from CFR are referenced or


repeated in NFPA and CGA documents.

2
CYLIN
REQU
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 containers are usually filled to only 80% of their


capacity to allow room for liquid propane to expand with an
increase in temperature.

Propane is non-toxic, but its vapor can be dangerous to inhale


because it can displace oxygen. Since propane vapor is heavier
than air, propane released in a confined space may settle in
low-lying areas. However, if there is sufficient air movement,
especially outdoors, the vapor will quickly dissipate in the air.

Propane liquid becomes very cold when released to the


atmosphere. This means if it comes in contact with your skin, it
can cause frostbite or freeze burns. For this reason, appropriate gloves or other personal protective equipment
resistant to propane should always be worn when filling containers. Your employer may require other safety
equipment, depending on your specific responsibilities, so be sure to check with your supervisor.

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.

3
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.

If for any reason you cannot recognize the smell of propane,


notify your supervisor immediately. Both you and your customers’
safety could depend on your ability to smell propane in the event
of a leak.

WHAT YOU SHOULD KNOW BEFORE HANDLING PROPANE CYLINDERS

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.

Uncontrolled Propane Leaks and Fires


An uncontrolled release of propane can be extremely dangerous and potentially cause a fire or an explosion.
If your facility is equipped with an emergency shutdown device, make sure you are aware of its location. In the
event of a propane emergency, you should always place personal and customer safety first.

Follow these steps:

1. Shut down the dispenser, if safe to do so.

2. Evacuate the area immediately.

Everyone in the building, or area affected by the emergency, should evacuate immediately to a safe distance.
Do not re-enter the area.

3. Call for help.

After you are at a safe distance from the affected area, call 911 or your local fire department.

When Help Arrives


Emergency responders, including firefighters, HAZMAT crews, and
emergency medical technicians, are the only personnel qualified
to provide leadership in emergencies involving propane. Your
company may have specific instructions for you to follow in both
routine and emergency situations, so you should always consult
your supervisor for more information.

4
CYLIN
REQU
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.

COMMON ELEMENTS OF DOT CYLINDERS


Cylinder bodies are typically made from either aluminum or steel.

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.

5
CYLINDER REQUALIFICATION

COMMON ELEMENTS OF DOT CYLINDERS


(CONTINUED)
Openings for valves and fittings are located in the
service end of the cylinder. The number of openings
depends on how the cylinder will be used.

Portable and exchange cylinders usually have one


combination service valve and pressure-relief valve
screwed into the top of the cylinder.

Vertical cylinders with 4 to 40 lb propane capacity


must be fitted with an overfilling prevention device, or
OPD.

OPD cylinder valves are distinctively marked and


equipped with a unique handwheel in the shape of a
modified triangle.

OPDs must not be treated as the primary means of


preventing overfilling.

Some existing cylinders are not required to be fitted


with an OPD.

These include:

•• Cylinders used in industrial truck service or


mower applications

•• Cylinders manufactured prior to 1998 and


designed for use in the horizontal position

•• Cylinders used for industrial welding and cutting


gases

6
LESSON 3: DOT CYLINDERS

To protect the cylinder valves, a wide metal band


called a “collar” is welded to the cylinder body.

Collars often incorporate handles for lifting and


moving. Cylinder valves should never be used to lift or
move a cylinder.

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.

The markings include the cylinder specification design


code, service pressure, cylinder tare weight, water
capacity in pounds, manufacturer name, and test or
requalification date.

Cylinder capacity is marked by the pounds of water it


can hold.

The tare weight is the weight of the cylinder when


empty and includes the weight of the cylinder valves,
but not the filling hose and nozzle.

Cylinders with the same water capacity can have


different tare weights, so each cylinder should be
treated individually.

All refillable cylinders must be requalified at regular


intervals. Requalification should be performed only by
trained individuals.

7
DISCOVERY – PORTABLE CYLINDER MARKINGS
CYLINDER REQUALIFICATION
LEARNING ACTIVITY

8
DISCOVERY – EXCHANGE CYLINDER MARKINGS
LESSON 3: DOT CYLINDERS

LEARNING ACTIVITY

9
CYLINDER REQUALIFICATION

When reading the original date or requalification markings:

•• A date without a letter indicates the next requalification must


be within 12 years.

•• The letter “S” following the date indicates the cylinder must be
requalified within seven years of the marked date.

•• The letter “E” following the date indicates that requalification


is required again within five years of the marked date.

•• The most recent requalification date must be marked on the


cylinder.

Cylinders that are out of qualification must NOT be refilled; rather,


they should be marked and set aside in a designated safe area.

Knowing about cylinder construction, components, and markings


will assist you in safely requalifying your customers’ cylinders.

Dates are for example only.

10
LESSON 3: DOT CYLINDERS

Steel cylinders subjected to fire must be requalified,


reconditioned, or repaired by the original
manufacturer or a DOT-authorized repair facility
before being placed back in service. Aluminum
cylinders subjected to fire must be removed from
service permanently.

Cylinders set aside because of defects must not


be refilled unless the cylinder has been repaired
properly or replaced by a trained and qualified
service technician. Contact your propane supplier for
assistance.

If you encounter a cylinder with XXXs over the DOT


specification number or marked “CONDEMNED” on the
shoulder, collar, or head, do not requalify it. Instead,
mark and set aside in a designated safe area.

Never look directly into a relief valve opening to


inspect it. Instead, use a mirror to safely inspect the
relief valve.

Valve accessories may get broken or lost, allowing dirt


or moisture to enter the valve. Inspect and replace any
faulty or missing dust caps.

Valves may also become damaged through improper


cylinder maintenance. For example, service personnel
may fail to use proper brushes around cylinder
openings when painting them. As a result, gauge
faces, “weep” holes in filler valves, and discharge
openings of relief valves may be blocked with paint.

If you find a blue-green corrosion on the brass portion


of the cylinder valve, the cylinder may have come in
contact with anhydrous ammonia, which is often used
to manufacture illegal drugs. If you encounter this
situation, set the cylinder aside in a designated safe
area and contact the local fire or police department.

11
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.

In addition, a consumer information or warning label must be


on all portable refillable cylinders of 100 lb propane capacity
or less.

Be sure to apply an appropriate warning label if the original


manufacturer’s label is not present or clearly legible.

12
CYLIN
REQU
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:

•• Approved for the commodity to be shipped.

•• Marked with the DOT specification approved for propane.

Periodic requalification ensures that a DOT cylinder is taken out of


service if it leaks or if damage substantially weakens the cylinder
during the period between requalifying inspections.

13
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

•• Every five years thereafter, if requalified by The process by which a DOT


external visual inspection. A date followed by cylinder under specified test
the letter “E” indicates a recorded external pressure is visually inspected for
visual inspection was performed at the last leaks or deformation.
requalification.

The requalification schedule can vary


for cylinder types other than 4B, 4BA,
4BW, and 4E. Specific details about
these alternate cylinder types are
presented later in this module.

Dates are for example only.

14
LESSON 4: DOT REQUALIFICATION REQUIREMENTS

REQUALIFICATION PERSONNEL
Persons who requalify cylinders using the external
visual inspection method must:

•• Be trained to apply applicable standards and


procedures.

•• Attend required refresher training every three


years after initial training.

•• Be thoroughly familiar with the applicable CGA


standards and DOT regulations that apply to
cylinder requalification.

•• Have a copy of all applicable CGA standards


and DOT regulations readily available. A copy
of CETP Basic Plant Operations or the Cylinder
Requalification Training Program are acceptable
for this purpose.

15
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:

•• Detailed requalification facility information.

•• Identification of the DOT Specification/Special Permit Cylinders to be inspected at the facility.

•• 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.

16
LESSON 4: DOT REQUALIFICATION REQUIREMENTS

REQUALIFICATION RECORDS AND REPORTS


DOT requires the retention of cylinder requalification reports and records. Reports and records must be
maintained at each facility where cylinders are requalified, repaired, rebuilt, or condemned.

Requalification

The process by which a DOT Rebuild


cylinder must be taken out of
service, retested, and found to be The replacing of a pressure part
suitable for continued service on by welding. For instance, welding
or before the required date. Most a new wall head or pressure
companies that are authorized fitting.
to requalify cylinders do so by
external visual inspection.

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.

17
CYLINDER REQUALIFICATION

REQUALIFICATION FACILITY RECORDS


Required facility records include:

•• Current copies of DOT regulations applicable to


cylinder requalification done at the facility.

•• A copy of the Compressed Gas Association (CGA)


or American Society for Testing and Materials
(ASTM) standards applicable to cylinder
requalification done at the facility, or a copy
of either CETP Basic Plant Operations or the
Cylinder Requalification Training Program.

•• A current requalification identification number


(RIN) issuance letter where applicable. Facilities
must reapply for the RIN every five years.

For more information on CGA and ASTM publications


providing standards for cylinder requalification, visit:

•• The CGA website at www.cganet.com.

•• The ASTM International website at


www.astm.org.

Requalification Identification
Number (RIN)

A code assigned to uniquely


identify a cylinder requalification,
repair, or rebuilding facility.

18
LESSON 4: DOT REQUALIFICATION REQUIREMENTS

RECORDS AND REPORTS


Requalification record pages for external visual The option to use a single date for each record page is
inspections must document the following: acceptable if each requalification inspection on that
page is done on that date.
•• Date of requalification
The use of ditto marks or a solid vertical line
•• Cylinder serial number to indicate repetition of the preceding entry is
•• DOT specification or special permit number acceptable for the following entries only.

•• Marked pressure, which is included in the DOT •• Date


specification number •• Actual dimensions
•• Actual dimensions of the cylinder •• Manufacturer’s name or symbol, if present
•• Manufacturer’s name or symbol •• Owner’s name or symbol, if present
•• Owner’s name or symbol, if present •• Test operator or inspector
•• Result of the visual inspection Blank spaces may not be used to indicate duplicate
•• Cylinder disposition, with reason for any repeated results of repeated operations.
test, rejection or condemnation

•• Legible identification of the test operator Cylinder Disposition


The cylinder disposition is the final determination
of the cylinder inspector as to its status. After
requalification inspection every cylinder is assigned
one of the following dispositions:

•• OK: The cylinder has passed the inspection


and is requalified for another five year period.

•• R or RM: Rejected or Removed from Service.


The cylinder must be repaired or rebuilt and
inspected again before it can be requalified.

•• SC: Scrapped or Condemned. The cylinder


must be permanently removed from service
by marking the cylinder or rendering it
incapable of holding pressure.

19
CYLINDER REQUALIFICATION

RECORDS RETENTION
Requalification records must be maintained at the
facility until either:

•• The expiration of the requalification period.

– or –

•• The cylinder is requalified again.

20
LESSON 4: DOT REQUALIFICATION REQUIREMENTS

CHECK FOR UNDERSTANDING – DOT REQUALIFICATION REQUIREMENTS


Select the appropriate answer for the following question. Check your work on page 125.

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.

DOT Requalification Schedule.

NFPA codes and standards.

Requalification reports and record retention specifications.

American National Standards Institute requirements.

External visual inspection personnel qualifications.

Department of Labor’s OSHA requirements.

21
CYLINDER REQUALIFICATION

22
CYLIN
REQU
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.

This lesson focuses specifically on steel DOT cylinders. Cylinders


manufactured with different materials are covered later in this
module.

23
CYLINDER REQUALIFICATION

REQUALIFICATION PROCESS OVERVIEW


There are four major steps in the requalification process. Each of the four major steps in the requalification
process plays an important role in ensuring that DOT cylinders are safe for continued propane service. The chart
below highlights activities done in each step.

Prepare Inspect Leak Test Process


Verify Fire exposure Leak test Mark (OK) and
requalification return to
date Distortions service

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

24
LESSON 5: REQUALIFICATION PROCESS OVERVIEW

PREPARE FOR THE INSPECTION


During the first step of the requalification process,
verify the cylinder date requirements, gather the
required inspection log forms, and prepare the
cylinder for inspection. These steps are important in
order to ensure:

•• If the cylinder is leaking, it should be removed


immediately from service.

•• The cylinder is within the time limit since the last


inspection or test date.

•• The inspection results can be recorded promptly


and accurately.

•• The cylinder is empty and sufficiently clean so as


not to hide any cylinder defects.

Prepare Inspect Leak Test Process


Verify Fire exposure Leak test Mark (OK) and
requalification return to
date Distortions service

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

25
CYLINDER REQUALIFICATION

INSPECT THE CYLINDER


During the next step, inspect the entire cylinder
thoroughly for signs of fire exposure or damage to any Appurtenances
part of the cylinder, including its appurtenances. You
In the case of propane cylinders,
should also check the cylinder and its valves for signs
appurtenances include attachments
of corrosion or distortions.
threaded or flanged directly to the
You should also weigh the empty cylinder during the container, such as valves and OPDs
inspection. It is important to verify that the cylinder that are not a permanent part of the
tare weight has not been reduced by corrosion beyond cylinder.
a safe tolerance.

This step in the cylinder requalification process


ensures that the cylinder shows no visible signs
of damage, corrosion, or fire exposure that would
prevent the cylinder from safely continuing service in
its current condition.

Prepare Inspect Leak Test Process


Verify Fire exposure Leak test Mark (OK) and
requalification return to
date Distortions service
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

26
LESSON 5: REQUALIFICATION PROCESS OVERVIEW

LEAK TEST THE CYLINDER


In this step of the cylinder requalification process,
test the cylinder for leaks by charging the cylinder
with propane vapor and using a suitable leak detector
solution or device.

Prepare Inspect Leak Test Process


Verify Fire exposure Leak test Mark (OK) and
requalification return to
date Distortions service

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

27
CYLINDER REQUALIFICATION

PROCESS THE CYLINDER


This final step in the cylinder requalification process ensures that
the cylinder disposition is documented, cylinders are marked
appropriately, and the report is prepared upon completion of the
requalification process.

Cylinders that pass the requalification inspection are:

•• Given a disposition of OK on the inspection report.

•• Marked with required information.

•• Returned to service.

Cylinders that do not pass the inspection are:

•• Given a disposition of Rejected/Removed from Service (R or RM) or Scrapped/Condemned (SC) on the


inspection report.

•• Marked appropriately.

•• If necessary, remove from service for repair or condemnation.

Regardless of the cylinder disposition, the inspection report must be completed fully for each cylinder.

Prepare Inspect Leak Test Process


Verify Fire exposure Leak test Mark (OK) and
requalification return to
date Distortions service
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

28
LESSON 5: REQUALIFICATION PROCESS OVERVIEW

CHECK FOR UNDERSTANDING – REQUALIFICATION PROCESS OVERVIEW


Select the appropriate answer for the following question. Check your work on page 125.

Match the cylinder requalification task with the appropriate part of the cylinder requalification process. Some
answers are used more than once.

_____ Determine the cylinder requalification date.

Prepare _____ Document and return a requalified cylinder to service.

Inspect _____ Obtain a visual inspection report form.

Leak Test _____ Check the cylinder for fire damage.

Process _____ Charge the cylinder with propane vapor.

_____ Weigh the empty cylinder.

29
CYLINDER REQUALIFICATION

30
CYLIN
REQU
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.

31
CYLINDER REQUALIFICATION

PREPARE FOR INSPECTION


This first question shown at the right helps you
determine whether or not the cylinder is due for
requalification. If the answer to this question is no,
then a simple pre-fill inspection is performed on the
cylinder to determine its suitability for continued
service.

If the answer to this question is yes, then the cylinder


must pass the entire requalification inspection in
order to be returned to service.

The chart below shows requalification periods for


DOT cylinders and is used to help you make this
determination. It lists:

•• The requalification periods for each type of


test or requalification required for various DOT
cylinders. Eight types of cylinders are listed in
the first column.

•• The second column lists the maximum length


of time in years allowed by DOT before a cylinder
must be requalified. Depending on the type of
DOT cylinder, the first required requalification
period may be 5 years or 12 years.

32
LESSON 6: PREPARE FOR REQUALIFICATION

REQUALIFICATION PERIODS FOR DOT


CYLINDERS
In order to determine if the cylinder is due to be
re-qualified, first look at the head or collar and read
the DOT specification number. In this example, the
DOT specification number shows it as a 4BW type of
cylinder.

If any of this information is illegible, the cylinder must


be requalified.

Then, read the month and year of the last test or


requalification. In this example, the last requalification
date is October of 2015.

Next, determine the type of test or requalification


procedure used for the last test or requalification.
Remember; determine this by reading the letter
immediately following the test or requalification date:

•• Test date without letters signifies a water jacket


volumetric expansion test.

•• Test date followed by the letter S signifies an


internal hydrostatic test.

•• Requalification date followed by the letter E


signifies external visual inspection.

If the maximum length of time allowed by the DOT


has been exceeded, it cannot be refilled until it is re-
qualified.

33
CYLINDER REQUALIFICATION

REQUALIFICATION PERIODS FOR DOT


CYLINDERS (CONTINUED)
Use of the cylinder markings and the chart below to •• The last test or requalification date was October
determine when the next requalification is due for the of 2015.
cylinder is summarized in this example:

•• The DOT specification number tells us the


cylinder is a 4BW type.

•• The test procedure used was an external visual


inspection.

•• Use the chart below to determine when the next


requalification is due.

•• The due date is the last day of October 2020.

34
LESSON 6: PREPARE FOR REQUALIFICATION

CHECK FOR UNDERSTANDING – PREPARE FOR REQUALIFICATION


Select the appropriate answer for the following question. Check your work on page 125.

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

35
CYLINDER REQUALIFICATION

VISUAL INSPECTION REPORT


After determining the cylinder is due for requalification, you must obtain
a Visual Inspection Report form. To document that every DOT cylinder is
properly requalified, you will fill out and file this form. Start by filling in the
form with basic cylinder information.

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 identification (cylinder serial number, DOT specification


or special permit number, marked pressure, actual dimensions
of the cylinder, manufacturer’s name or symbol, date of manufacture,
and owner’s name or symbol, if present).

•• Type of cylinder protective coating


including a statement as to
the need of refinishing or
recoating.

•• Conditions to check for on the


cylinders, for example leaks,
corrosion, gouges, dents, or
digs in shell or head; broken
or damaged foot ring or
protective ring; or fire damage.

•• Cylinder disposition:

–– Return to service is indicated


on the form with OK.

–– 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.

–– Scrapped/Condemned is indicated on the form with SC.


The reason for the condemnation must also be documented.

•• Legible identification of the inspector.

36
LESSON 6: PREPARE FOR REQUALIFICATION

EMPTY THE CYLINDER


If the cylinder to be requalified contains liquid
propane, it may be required to be emptied or
evacuated before proceeding with the inspection.

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.

If you are not trained to evacuate cylinders, contact


your fuel supplier. Attempting to evacuate without
the appropriate equipment can lead to incomplete
evacuations, potential injuries, and the possibility of
an unintentional release of propane.

The area around the evacuation operations must be


free of any ignition sources.

The two conventional methods used to evacuate liquid


propane are:

•• Differential pressure evacuation, also known as


the gravity method.

•• Compressor system evacuation.

The following pages examine these evacuation


methods in detail.

37
CYLINDER REQUALIFICATION

Differential Pressure Evacuation (Gravity Method)

Differential pressure evacuation allows you to remove


propane liquid from portable and exchange DOT
cylinders using gravity to do the work. Transfer of
liquid is accomplished by inverting the cylinder in
an elevated position above a receiving container
approved for propane storage.

1. Invert the cylinder in an elevated position above a


propane approved receiving container. Larger
cylinders, especially exchange cylinders that do not
have collars to protect the service valve, should be
secured in a cylinder inverter rated for the cylinder
size.

2. Connect the two containers with a high-pressure


propane hose assembly.

3. Open the service valve on the cylinder to be


evacuated and allow the liquid to drain into the
receiving container. The liquid will stop flowing as
soon as the pressure between the two containers
equalizes. To completely evacuate the cylinder, you Cylinder Inverter with
Securing Straps
may need to utilize another empty cylinder or use
the compressor method to decrease the vapor High Pressure LP-Gas
Hose with Excess Flow &
pressure in the receiving container. Shutoff Valve Each End

This process allows the liquid in the receiving


container to be recovered and used.

Receiving
WARNING: Be careful not to overfill ASME Tank
Elevated Dock or Platform

the receiving container.

38
LESSON 6: PREPARE FOR REQUALIFICATION

COMPRESSOR SYSTEM EVACUATION


Another method to evacuate liquid propane uses a
compressor and an assembly called the scavenging
system.

Scavenging System Components


The system consists of three propane containers:

•• The cylinder needing evacuation.

•• A scavenging tank.

•• A storage tank.

The compressor and a series of fixed piping and hoses


complete the system.

39
CYLINDER REQUALIFICATION

SCAVENGING SYSTEM PATH


If you are not properly trained and/or do not have experience evacuating containers, ask your supervisor for
assistance.

When evacuating the cylinder, do the following:

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.

2. Turn on the compressor.

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:

1. Turn off the compressor.

2. Close all valves.

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.

4. Turn on the compressor.

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.

40
LESSON 6: PREPARE FOR REQUALIFICATION

COMPRESSOR SYSTEM EVACUATION ON LIQUID SERVICE CYLINDERS


Cylinders designed for liquid service use a:

•• Liquid service valve.

•• 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

41
CYLINDER REQUALIFICATION

COMPRESSOR SYSTEM EVACUATION ON


VAPOR SERVICE CYLINDERS
Cylinders designed for vapor service do not utilize
a dip tube. Therefore, the cylinder is inverted. To do
this safely, a cylinder inverter is used to support the
Inverter
cylinder.

Once inverted, a liquid transfer hose is connected


between the cylinder’s service valve and the
scavenging tank. The liquid then flows through the
vapor service valve.

Complete evacuation of vapor service cylinders is


possible using this method.
Service Valve

Scavenging Tank

42
LESSON 6: PREPARE FOR REQUALIFICATION

CHECK FOR UNDERSTANDING – PREPARE FOR REQUALIFICATION


Select the appropriate answer for the following question. Check your work on page 125.

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?

Bleed the lines connected to the storage tank.

Invert the tank with a heavier-load-rated inverter.

Reverse the vapor line connections or change the position of the four-way valve.

Vent the scavenger tank.

43
CYLINDER REQUALIFICATION

Check your work on page 125.


LEARNING ACTIVITY: EVACUATING CYLINDERS

44
LESSON 6: PREPARE FOR REQUALIFICATION

CLEAN AND PREPARE THE CYLINDER


To properly clean and prepare the cylinder for
inspection, you must:

1. Make sure that you are working at a safe distance


from flammable liquids and combustible materials.

2. Remove the cylinder sleeve, if present.

3. Remove any rust, scale, caked paint, or other


foreign matter from the exterior surface of the
cylinder so it is adequately prepared for inspection.

4. Remove any coating, rust, or scale from welds and


joints where any part is joined to the cylinder body.

5. Mark any area of the cylinder where a dent, dig, cut,


corrosion, or fire damage is evident using chalk or
another non-permanent marking device.

45
CYLINDER REQUALIFICATION

CHECK FOR UNDERSTANDING – PREPARE FOR REQUALIFICATION


Select the appropriate answer for the following question. Check your work on page 126.

When preparing to perform a requalification inspection, you must:

Select all that apply.

Remove any rust, dirt, or caked paint from the cylinder surface.

Remove all valves from the cylinder.

Obtain a Visual Inspection Form.

Determine the requalification date.

Use permanent paint to circle any cuts, gauges, dents, bulges, digs, fire damage, or other problem
areas.

Empty the cylinder of any liquid propane.

46
CYLIN
REQU
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.

47
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.

Typically, exposure to fire is normally determined by


visual examination with attention paid to the condition Common evidence of fire exposure includes:
of the protective coating, as outlined in C-6. If there is •• Charring or burning of the paint or other
evidence that the protective coating has been burned protective coating.
off any portion of the cylinder surface or if the cylinder
body is burned, warped, or distorted, assume that the •• Burning or scarfing of the metal.
cylinder has been overheated. But if the protective
coating is only smudged, discolored, or blistered and •• Distortion of the cylinder.
is intact underneath, the cylinder is not considered
•• Burning or melting of the valve(s).
affected within the scope of this requirement.
Scarfing
Scarfing is the appearance that
the surface area of a metal
object has been exposed to the
heat of a gas torch.

48
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER

FIRE DAMAGE (CONTINUED)


To ensure that the paint is not damaged, wash off any
soot. If there is doubt, scrape off any charred paint
and check for discoloration in the metal.

Check the cylinder for excessive distortion such as


leaning or bulges, especially in any area where there is
charring or burn indications on the paint or protective
coating.

If the cylinder does not show significant evidence of


fire damage, you will continue to the next inspection
step of checking the cylinder for distortion. However,
if there is significant fire damage, proceed to the
next question: “Can/will the cylinder be requalified by
volumetric expansion test (water jacket method?).”

Requalification Restrictions for Fire Exposure

If the cylinder shows significant fire damage, you


must refer to your company policy or contact your
fuel supplier for additional guidance. Water jacket
volumetric expansion testing carries a cost. Some
marketers may reject fire-damaged cylinders and
send them out for testing, repair, and requalification.
Other marketers may choose to condemn cylinders in
the same condition.

49
CYLINDER REQUALIFICATION

REJECTION CRITERIA FOR FIRE EXPOSURE


The only way to requalify a steel cylinder subjected to
fire damage is by volumetric expansion testing using
the water jacket method.

If your company sends cylinders out for this type of


testing, reject the cylinder, noted with R or RM on the
form, because of fire damage if any of the following
are present:

•• Valve is burned or melted.

•• Paint or protective coating is burnt or charred.

•• Cylinder body is burnt, warped, or distorted.

50
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER

CONDEMNATION CRITERIA FOR FIRE


EXPOSURES
DOT regulations require that a cylinder be rejected
or condemned if there is evidence of fire exposure.
The choice to either reject/remove from service(RM)
or scrap/condemn (SC) the cylinder should be made
according to your company policy.

If your company does not send fire-damaged cylinders


out for water jacket volumetric expansion testing, a
cylinder showing any of the rejection criteria listed
previously must be condemned, and noted with SC on
the form, rather than rejected.

51
CYLINDER REQUALIFICATION

CHECK FOR UNDERSTANDING – PERFORM AN INSPECTION ON A STEEL CYLINDER


Select the appropriate answer for the following question. Check your work on page 126.

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.

Packing seal and soft valve seat are decomposing.

Hand wheel is warped.

Protective cap missing.

Blue-black discoloration on the metal.

Bubbled cylinder coating.

52
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.

Determine if the cylinder is distorted to the extent


that it no longer supports itself or has bulged in one or
more areas on the body.

To inspect the cylinder for distortion:

1. Place the cylinder on a solid, level base. Position it


in the same manner as it is when in service.

2. Check the cylinder for bulges in the head or side of


the body.

If the cylinder does not show any significant distortion,


the cylinder can proceed to the next step of the
inspection process.

53
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:

1. With a six-foot (minimum) tape measure, measure


and mark halfway between the top and bottom of
the cylinder. Then, draw a line around the cylinder at
the mark. Use a waist seam for the mark where
possible.

3. Measure and record the circumference halfway


between the mark or waist seam and the top of the
cylinder. Repeat this step at the halfway point
between the mark or waist seam and the bottom of
the cylinder.

54
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER

CONDEMNATION CRITERIA FOR GENERAL


DISTORTION
Cylinders with more than 1% distortion must
be scrapped/condemned (SC). Use the cylinder
measurements to determine if the cylinder distortion
exceeds 1%. There are two methods you can use to
make this determination:
2. The difference between any two circumference
1. The difference between any two of the measurements exceeds 1%.
measurements between the top of the cylinder
and the mark exceeds 1%. Example:
Measurements of 55 in., 55 in, and 55.1 in.
Example:
Difference of .1 in. One percent of 55 in. is
Measurements of 16 in., 16.4 in., and 16 in.
.01 X 55 = .55 in.
Difference of .4 in. One percent of 16 in. is .01 X
16 = .16 in.
16”

55”

55.1”
16.4”

16” 55”

In this example, the difference of .1 in. is less


In this example, the difference of .4 in. is greater
than one percent (.55); therefore, the cylinder is
than 1% (.16 in.); therefore, the cylinder is out of
within tolerance and should proceed to the next
tolerance and must be condemned (SC), and
step in the inspection process.
processed appropriately.

55
CYLINDER REQUALIFICATION

CYLINDER LEANING Requalification Restrictions for Leaning


If the cylinder has passed the check for general If the cylinder shows excessive leaning, you must ask
distortion, check whether the cylinder is leaning. To yourself whether the cylinder can or will be repaired
check the cylinder for leaning: and requalified based on your company policy. Based
on the extent of the damage and/or the cost of repair,
1. Place the cylinder on a solid, level base. Position it your company may choose to reject/remove from
in the same manner as it is when in service. service (RM) and repair cylinders in this condition or
scrap/condemn (SC) them.
2. Check the cylinder for excessive leaning due to a
damaged or distorted foot ring.

If the cylinder does not lean when placed on a level


base, the cylinder can proceed to the next step in the
inspection process.

Rejection Criteria for Leaning


If the cylinder is leaning to the extent that it could
easily tip over, it must be either rejected/removed
from service (RM) or scrapped/condemned (SC). If
the damage can or will be repaired, reject the cylinder
(RM) and proceed to processing.

Condemnation Criteria for Leaning


If the cylinder is leaning and cannot be repaired in this
condition, then scrap/condemn the cylinder (SC) and
proceed to processing.

56
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER

DAMAGE TO VALVE OPENINGS (NECK)


Determine if there is damage to the cylinder valve
openings or neck. The term “neck” refers to the
service valve opening in cylinders that contain only
one top opening or service end. The term is used
typically with portable and exchange cylinders.

Stationary and motor fuel cylinders usually contain


more than one opening. In either case, check all valve
openings for damage.

To complete this step:

•• Visually check for cracks, folds, and other flaws


in the neck or area where the valve openings are
joined to the top of the cylinder.

•• Check the neck or valve opening for general


distortion.

•• Where applicable, check for stripping, cracking,


corrosion, and chipping of the male threads used
for mounting the protective cap to the cylinder.

57
CYLINDER REQUALIFICATION

DAMAGE TO VALVE OPENINGS (NECK)


(CONTINUED)
Cylinder neck threads are examined whenever the
valve is removed from the cylinder. Cylinders have a
specified number of full threads of proper form as
required in applicable thread standards.

Acceptance criteria for continued use of the cylinder


threads require the following:

•• At least five continuous full threads for tapered


threads on propane cylinders.

•• No visible cracks in the threads or adjacent


visible areas.

•• No visible damage from corrosion or other


sources that might adversely affect the
structural integrity of the threads or valve
installation.

Cylinders manufactured to a specification with less


than the previously mentioned number of threads
need to retain all threads in a full, continuous,
undamaged condition for requalification and/or
continued service.

If the cylinder does not show any significant damage


to the valve openings, the cylinder can proceed to the
next step of the inspection process.

58
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER

REQUALIFICATION RESTRICTIONS FOR


VALVE OPENING DAMAGE
If the cylinder shows damage to the valve openings,
your company may choose to reject/remove from
service (RM) and repair cylinders in this condition
or simply scrap/condemn (SC) them. The cylinder
may also be rejected until the inspector determines
whether repair is feasible.

59
CYLINDER REQUALIFICATION

REJECTION CRITERIA FOR VALVE OPENING


DAMAGE

Reject/remove from service the cylinder due to valve


opening damage, noted with RM on the form, if any
of the following are present AND the cylinder may be
repaired:

•• The neck or valve opening is noticeably tilted or


sunken.

•• The neck or valve opening is cracked.

CONDEMNATION CRITERIA FOR VALVE


OPENING DAMAGE

Scrap/condemn the cylinder, noted with SC on the


form, due to valve opening damage if any of the
previous rejection criteria are present, AND the
cylinder will not or cannot be repaired.

60
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER

CHECK FOR UNDERSTANDING – PERFORM AN INSPECTION ON A STEEL CYLINDER


Select the appropriate answer for the following question. Check your work on page 126.

The term “neck” refers to the _______________ opening in cylinders that contain only one top opening or service
end.

Service valve.

Pressure relief valve.

Filler valve.

Fixed maximum liquid level gauge.

61
CYLINDER REQUALIFICATION

DAMAGE TO CYLINDER ATTACHMENTS


Next, identify if there is damage to the cylinder
attachments.

Cylinder attachments are parts that are welded or


brazed to the cylinder body for protection, installation,
or identification. Do not attempt to weld a repair.
Typical cylinder attachments are collars, foot rings,
and supports.

NOTE: If a double or false bottom is present on the


cylinder, it has been tampered with and should be
removed from service immediately.

Check all cylinder attachments for serviceability. Do


the following checks:

•• Inspect the collar.

•• Look for distortion or damage that would limit or


prevent it from protecting the cylinder valves.

•• Look for corrosion or cracking where the collar


joins the cylinder body.

62
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER

DAMAGE TO CYLINDER ATTACHMENTS


(CONTINUED)
Next, invert the cylinder and inspect the foot ring or
supports:

•• Look for distortion that would prevent it from


supporting the cylinder properly in an upright,
stable position.

•• Look for cracking or corrosion where it joins the


cylinder body.

If there is no significant damage to the cylinder


attachments, the cylinder can proceed to the next
step of the inspection process.

63
CYLINDER REQUALIFICATION

REQUALIFICATION RESTRICTIONS FOR


CYLINDER ATTACHMENT DAMAGE
If the cylinder shows damage to the attachments, your
company may choose to reject/remove from service
(RM) and repair cylinders in this condition or simply
scrap/condemn (SC) them. The cylinder may also be
rejected until the inspector determines whether repair
is feasible. Only a qualified person can make these
types of repairs.

64
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER

REJECTION CRITERIA FOR CYLINDER CONDEMNATION CRITERIA FOR CYLINDER


ATTACHMENT DAMAGE ATTACHMENT DAMAGE
Reject/remove from service the cylinder, noted with Scrap/condemn the cylinder, noted with SC on the
RM on the form, due to cylinder attachment damage if form, due to cylinder attachment damage if any of the
any of the following are present, AND the cylinder may rejection criteria above are present AND the cylinder
be repaired based on your company policy: will not or cannot be repaired based on your company
policy.
•• The collar is loose or shifted, damaged to the
extent it cannot protect the cylinder valves, or
weld points are damaged or cracked.

•• The foot ring is loose or shifted, damaged to the


extent it cannot support the cylinder in a straight
or upright position, or weld points are damaged
or cracked.

65
CYLINDER REQUALIFICATION

CHECK FOR UNDERSTANDING – PERFORM AN INSPECTION ON A STEEL CYLINDER


Select the appropriate answer for the following question. Check your work on page 126.

To inspect the cylinder foot ring or supports, you must:

Empty the cylinder.

Elevate the cylinder.

Invert the cylinder.

Weigh the cylinder.

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.

A dent is an area of the cylinder that is deformed or


pushed in by colliding with a blunt object. Typically, a
dent does not reduce the thickness of the metal. It
could if the dent is deep and confined to a small area
or is near a weld.

For these reasons, dents in the cylinder must be


measured and checked carefully. When a dent is
detected, measure the dent by doing the following:

1. Obtain two carpenter or metal straight-edge rulers.


Locate the dent.

2. Check if the dent includes a weld.

3. Use a straight edge to measure the average overall


diameter or dimension of the dent.

4. Measure the dent depth to nearest 1/100th of an


inch. Use an industrial depth gauge if needed.

5. Record the greatest dimension of the dent and the


dent depth on a separate sheet of paper.

6. Repeat this process for each dent.

67
CYLINDER REQUALIFICATION

DAMAGE LIMITS FOR CYLINDER DENTS


After measuring the dents in the cylinder, ask yourself if any of the
dents:

•• Are on a weld and more than 1/4th inch deep, or

•• 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

•• Exceed the maximum


allowable dent depth for the
average diameter as shown
in the chart Maximum Dent of
Depths Allowed for DOT/ICC
cylinders.

If the cylinder dents are within


tolerance, the cylinder may
proceed to the next step of the
inspection process; checking the
cylinder for cuts, gouges, and digs.

NOTE: This chart is for reference


only.

68
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER

CONDEMNATION CRITERIA FOR CYLINDER


DENTS
If you discover that any of the dents are out of
tolerance based on your measurements, scrap/
condemn (SC) the cylinder and proceed to processing.

Cylinders with dents that are out of tolerance must be


condemned, they cannot be reparied.

69
LEARNING ACTIVITY: REQUALIFICATION OF DOT CYLINDERS
CYLINDER REQUALIFICATION

Check your work on page 126.

70
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER

MINIMUM ALLOWABLE DESIGN THICKNESS TABLE


The next two cylinder requalification checks include inspecting the cylinder for:

•• cuts, gouges, or digs

•• 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.

71
CYLINDER REQUALIFICATION

CUTS, GOUGES, OR DIGS


Check the cylinder for significant cuts, gouges, or digs.

A cut, gouge, or dig is an area of the cylinder that is


deformed or distorted by a sharp object. Typically, the
wall thickness is reduced and weakened at this point.

In order to inspect the cylinder for damage due to


cuts, gouges, or digs, do the following:

1. Obtain a carpenter’s rule and an industrial depth


gauge.

2. Locate the cut, gouge, or dig in the cylinder’s body.

3. Measure the overall length of the cut, gouge, or dig.


Pit Guage
4. Measure the depth of the cut, gouge, or dig with the
depth gauge. If there is a sliver of metal in the
groove, remove the sliver before measuring the
depth.

5. Record the depth on a separate sheet of paper.

6. Repeat the process for each cut, gouge, or dig on


the cylinder. Original Maximum Loss of Wall Due
Wall Thickness to Pitting and Corrosion

Remaining
Wall Thickness

72
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER

DAMAGE LIMITS FOR CUTS, GOUGES, AND


DIGS
Based on your measurements and the damage limits
shown on the LP-Gas Cylinder Damage Limits table
shown on the following page, you must consider
whether any of the cuts, gouges or digs are outside of
the specified damage limits.

If cuts, gouges, or digs are within damage limits,


the cylinder may proceed to the next step of the
inspection.

73
CYLINDER REQUALIFICATION

DAMAGE LIMITS FOR CUTS, GOUGES, AND DIGS (CONTINUED)

NOTE: This table is for reference only.

74
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER

CONDEMNATION CRITERIA FOR CYLINDER


CUTS, GOUGES, AND DIGS
If you discover that any of the cuts, gouges, or digs are
out of tolerance based on your measurements, scrap/
condemn (SC) the cylinder and proceed to processing.
Specifically, scrap/condemn the cylinder when:

•• The cut, gouge, or dig is less than 3 inches long


and deeper than the dimension shown in Column
1 of the chart.

•• The cut, gouge, or dig is more than 3 inches


long and deeper than the dimensions shown in
Column 2 of the chart.

Cylinders with cuts, gouges, or digs that are out of


damage limits must be scrapped/condemned. They
cannot be repaired.

75
CYLINDER REQUALIFICATION

CHECK FOR UNDERSTANDING – PERFORM AN INSPECTION ON A STEEL CYLINDER


Select the appropriate answer for the following question. Check your work on page 126.

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.

Industrial depth gauge.

T-square.

76
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER

ISOLATED PITTING, LINE CORROSION, AND


GENERAL CORROSION
If the cylinder you are inspecting did not show any
significant cuts, gouges, or digs, your next step is to
inspect for any significant evidence of corrosion on
the cylinder.

Corrosion or pitting in cylinders is a serious problem


that results in the loss of wall thickness of the metal.
The potential for a cylinder to fail may be related to
corrosion in areas that are not readily visible, as in the
You must make sure to check the bottom of the
case of isolated pitting.
cylinder inside the ring for corrosion during your
Corrosion that could cause a cylinder to fail may not inspection. This is the area of a cylinder that is most
be visible without close inspection of all areas of the likely to get wet and stay wet for long periods, thereby
cylinder. Dirt, paint, or rust can potentially cover an increasing the potential for corrosion.
area of isolated pitting. This is part of the reason
that the cylinder must be clean before you begin the
inspection.

Corrosion may appear in several forms:

•• Isolated pitting may appear in a small area of


the cylinder. Although this does not weaken
the cylinder wall appreciably, it may eventually
corrode through the wall and cause
a leak.

•• Line corrosion may appear in a narrow band or


a line that may weaken the cylinder wall. Crevice
corrosion looks like line corrosion but occurs at
the intersection of the neck or foot ring and the
body of the cylinder.

•• General corrosion may cover a considerable


area of the cylinder. General corrosion usually
contains areas of heavy pitting and does not
always follow a definite pattern. Typically,
general corrosion reduces the wall thickness and
structural strength of a large area.

77
CYLINDER REQUALIFICATION

ISOLATED PITTING, LINE CORROSION, AND


GENERAL CORROSION (CONTINUED)
To inspect the cylinder for corrosion, each type of 4. Measure general corrosion as follows:
corrosion is identified and measured. To complete this
task, do the following: •• Measure the depth of the pitting using the
depth gauge or scriber in several places.
1. Obtain a carpenter’s rule and an industrial depth
gauge or scriber. •• Record the location (shell or head) and the
depth of the deepest pit on a separate sheet of
2. Measure isolated pitting as follows: paper.

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.

•• Use the depth gauge to measure the depth of


the isolated pitting in several places.

•• Record the location, such as shell or head,


and the depth of the deepest pit on a separate
sheet of paper.

•• Repeat until all areas of isolated pitting are


measured and recorded.

3. Measure line corrosion as follows:

•• Measure the length using the carpenter’s rule.

•• Measure the depth of the pitting using the


depth gauge in several places. Do as many
measurements as necessary. If crevice
corrosion is present, use a scriber to measure
the crevice corrosion.

•• Record the location, length, and depth of the


deepest line corrosion on a separate sheet of
paper.

•• Repeat until all areas of the line and crevice


corrosion are measured and recorded.

78
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER

CORROSION DAMAGE LIMITS


Based on your measurements and the damage limits
shown on the LP-Gas Cylinder Damage Limits table
on the following page, you must next ask yourself if
any of the isolated pitting, line corrosion, or general
corrosion is outside of the specified damage limits.

If corrosion is within damage limits, the cylinder may


proceed to the next step of the inspection.

79
CYLINDER REQUALIFICATION

CORROSION DAMAGE LIMITS (CONTINUED)

NOTE: This table is for reference only.

80
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER

CONDEMNATION CRITERIA FOR CYLINDER


CORROSION
Typically, corrosion is permanent damage that
reduces the wall thickness. If you discover that any
of the corrosion on the cylinder is outside of the
damage limits, based on your measurements, scrap/
condemn (SC) the cylinder and proceed to processing.
Specifically, scrap/condemn the cylinder when any of
the following are present:

•• Isolated pitting: The measured depth of pitting


is greater than the maximum permitted depth
shown in Column 3 of the LP-Gas Damage Limits
table.

•• Line corrosion less than 3 in. long: The


measured depth of pitting is greater than the
maximum permitted depth shown in Column 1,
Line corrosion…less than 3 in. long of the table.

•• Line corrosion more than 3 in. long: The


measured depth of pitting is greater than the
maximum permitted depth shown in Column 2,
Line corrosion…more than 3 in. long, of the table.

•• General corrosion: The measured depth of


pitting is greater than the maximum permitted
depth shown in Column 4, Pits in General
Corrosion Area, of the table.

Cylinders with any type of corrosion that is outside of


damage limits must be scrapped/condemned, they
may not be repaired.

81
CYLINDER REQUALIFICATION

CHECK FOR UNDERSTANDING – PERFORM AN INSPECTION ON A STEEL CYLINDER


Select the appropriate answer for the following question. Check your work on page 126.

Identify the type of corrosion that is NOT defined in the cylinder requalification procedure.

General corrosion.

Weld corrosion.

Isolated pitting.

Line corrosion.

82
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER

TARE WEIGHT CHECK


If the cylinder you are inspecting does not have any
significant corrosion, the next step is to ask yourself
if the empty cylinder has lost more than 5% of its
marked tare weight.

Weigh the empty cylinder to determine if the


combined damage due to cuts, corrosion, and so forth,
has reduced the tare weight by more than 5%.

Do this procedure only after all liquid is evacuated


from the cylinder.

1. Move the cylinder to the scale.

2. Position it according to the scale manufacturer’s


instructions.

3. Weigh the cylinder with the service valve installed


and protective caps removed.

4. Follow the scale manufacturer’s instructions for


weighing the cylinder and record the weight.

Next, do the following:

1. Check the stamped markings on the cylinder and


record the marked tare weight.

2. Multiply the tare weight by .95 to determine the


minimum tare weight allowed for the cylinder.

For example, if the tare weight is 144 pounds, then the


minimum allowable tare weight is:

144 X .95 = 136.8 pounds.

If you determine that the cylinder has not lost more


than 5% of its marked tare weight, the cylinder may
proceed to the leak test portion of the requalification
inspection.

83
CYLINDER REQUALIFICATION

CONDEMNATION CRITERIA FOR CYLINDER


WEIGHT
Scrap/condemn (SC) the cylinder if the cylinder tare
weight is reduced by more than 5%. In these cases, it
is typically not strong enough to be repaired or placed
back into service.

NOTE: There is one exception to condemning a


cylinder with 5% or more tare weight reduction. CGA
C-6 stipulates that if the weight loss of the marked
tare weight is between 95% (5% loss) and 90%
(10% loss), the cylinder may be requalified only by
volumetric expansion or proof pressure testing. Most
cylinder requalifiers are not authorized to do these
tests. The cost of shipping to an authorized site and
testing may be prohibitive. Therefore, cylinders are
typically scrapped/condemned if the tare weight is
less than 95% (more than 5% loss) of the original
stamped tare weight. Check with your supervisor for
instructions.

84
LESSON 7: PERFORM AN INSPECTION ON A STEEL CYLINDER

CHECK FOR UNDERSTANDING – PERFORM AN INSPECTION ON A STEEL CYLINDER


Select the appropriate answer for the following question. Check your work on page 126.

A cylinder that has lost more than ________% of its marked tare weight should be condemned.

15

85
CYLINDER REQUALIFICATION

86
CYLIN
REQU
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?

The decision chart includes the questions you must YES

ask yourself while leak testing a cylinder that has NO

successfully passed the Inspect portion of the


requalification process. To view the entire decision Leak at
cylinder
Threaded opening
still leaking after Reject cylinder,
YES
chart for the DOT cylinder requalification by visual threaded
YES
resealing and mark report RM.
Continue to
opening(s)? retesting for leaks?
inspection process, see Resources. Step 4: Process
NO

Leak somewhere other Condemn cylinder, mark


YES report SC.
than a threaded opening?
Continue to Step 4: Process

87
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.

Because of the possibility of a leak, this test should


be performed by charging the cylinder with propane
vapor. Do not use propane liquid.

In addition to the leak test procedures described here,


some marketers and/or cylinder manufacturers may
recommend performing additional checks at this
point in the requalification process. For example, your
company may recommend exercising the actuated
valves on the cylinder during the leak test. For more
information about additional recommended checks
during leak testing, see your company policy and/or
the manufacturer’s instructions.

To leak test the cylinder:

1. Install all cylinder valves and accessories using the


appropriate wrench and thread sealing compound.

2. Ensure the service valve is closed.

3. Carefully move the cylinder to a filling station and


connect the vapor hose to the cylinder.

4. Carefully open the shutoff valve on the end of the


vapor hose.

5. Carefully open the service valve.

6. Charge the cylinder until pressure equalizes.

7. Shut off and disconnect the vapor equalizing hose


carefully.

88
LESSON 8: TEST FOR LEAKS

LEAK TEST (CONTINUED)


8. If an electronic leak detector is used, operate the
detector according to the manufacturer’s operating
instructions. If a leak detector solution is used,
apply it to the following areas:

•• Cylinder valve threads.

•• All welded seams.

•• All points where neck and foot rings are joined


to the cylinder body.

•• All areas that had severe corrosion, cuts, digs,


or dents.
9. Visually check all areas where the leak detector
solution has been applied.

10. Mark any area of the cylinder that is leaking if leaks


are found.

11. Bleed down the cylinder carefully.

12. Close the service valve.

13. Determine if the cylinder needs additional purging.


If not, remove the purging adapter from the service
valve outlet.

14. Store all tools and equipment.

If no leaks are found, the cylinder has passed


inspection. Mark the cylinder as OK on the inspection
form. Make sure you have documented the entire
process properly.

89
CYLINDER REQUALIFICATION

THREADED OPENING LEAKS RESEAL AND RETEST VALVE THREADED


OPENINGS

If the threaded opening is still leaking after resealing


the threads and retesting for leaks, the cylinder must
be rejected/removed from service (RM) and set aside
in a safe area for further repairs and requalification or
call your propane supplier.
If leaks are detected during the leak test, the next
question you must ask yourself is if the leak is at a
threaded opening in the cylinder or somewhere else
on the cylinder.

If leaks are present on the cylinder at a location


other than a threaded opening, the cylinder must
be scrapped/condemned (SC) and processed
accordingly. If leaks are present only at threaded
openings, you must reseal the threads and perform
the leak test again.

90
LESSON 8: TEST FOR LEAKS

REJECTION CRITERIA FOR CYLINDER CONDEMNATION CRITERIA FOR CYLINDER


LEAKS LEAKS

The cylinder must be scrapped/condemned, noted


with SC on the form, if the cylinder leaks in any area
other than a threaded opening, such as at welded or
If the cylinder valve threads indicate a leak, the
brazed seams, sharp dents, digs, gouges, or pits in the
cylinder valve should be resealed and tested for
cylinder body.
leakage again. Reject/remove from service the
cylinder, noted with RM on the form, if the cylinder
threaded opening continues to leak.

91
CYLINDER REQUALIFICATION

92
CYLIN
REQU
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.

93
CYLINDER REQUALIFICATION

CYLINDER PASSED INSPECTION (OK)


The first question you must ask yourself is if
the cylinder passed inspection and has been
marked appropriately with OK on the Visual
Inspection Report form. If the cylinder has
successfully passed the inspection, it must be
marked on the collar with a die stamp or some
other permanent marking before it can return
to service.

The marking for cylinders that have passed inspection must include the following information:

•• The requalification identification number or RIN.

•• 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.

•• Other method that produces a legible, durable mark.

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.

94
LESSON 9: PROCESS THE CYLINDER

CYLINDER REJECTED/REMOVED FROM SERVICE (RM)


If the cylinder did not pass the requalification inspection, the next question you must ask is if the cylinder was
rejected and the report marked with RM.

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.

To mark a rejected cylinder, do the following:

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.

95
CYLINDER REQUALIFICATION

CYLINDER SCRAPPED/CONDEMNED (SC)


If the cylinder did not pass the requalification inspection and was not rejected, it must be noted with an SC
on the inspection form. When a cylinder is scrapped/condemned (SC), it must be removed immediately from
service and appropriately marked.

To process a scrapped/condemned cylinder, do the following:

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.

96
LESSON 9: PROCESS THE CYLINDER

CHECK FOR UNDERSTANDING – PROCESS THE CYLINDER


Select the appropriate answer for the following question. Check your work on page 126.

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.

Render the cylinder incapable of holding pressure.

Note the cause of the rejection in the Comment section.

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.

97
CYLINDER REQUALIFICATION

98
CYLIN
REQU
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.

99
CYLINDER REQUALIFICATION

REQUALIFY ALUMINUM CYLINDERS


Generally, aluminum cylinders go through the same
requalification inspection as steel cylinders. However,
due to the differences between steel and aluminum
in material strength, corrosion resistance, and other
factors, the criteria used to determine rejection or
condemnation for aluminum cylinders is different
from steel in several cases.

The following table provides a side-by-side


comparison of the differing requirements for
requalification of steel and aluminum cylinders. For
further information or clarification, see:

•• CGA C-6 Standards for Visual Inspection of Steel


Compressed Gas Cylinders.

•• CGA C-6.3 Standards for Visual Inspection and


Requalification of Low- Pressure Aluminum
Compressed Gas Cylinders.

100
LESSON10:SPECIALREQUALIFICATIONCONSIDERATIONSFORCERTAINCYLINDERMATERIALSANDTYPES

Requalification Check for Steel and Aluminum Cylinder Requirements


Requalification Check Steel Cylinder Requirements (CGA C-6) Aluminum Cylinder Requirements (CGA C-6.3)
Cleaning prior to Remove all rust, scale, caked paint or coatings so Same as steel, but only products suitable for use
inspection the surface is adequately prepared for inspection. with aluminum should be used to avoid damage
to the metal.
Fire Damage Reject and send for repair, or condemn a steel Condemn an aluminum cylinder that shows
cylinder that shows evidence of fire damage. evidence of fire damage.
Corrosion limits 1. Condemn a steel cylinder when the remaining wall 1. Condemn an aluminum cylinder when the
thickness in area of isolated pitting is less than 1/3 corrosion depth is more that 15% of minimum
of the minimum allowable design thickness (MADT). wall thickness.** In addition, the area of
corrosion shall not extend over more than 15%
2. Condemn a steel cylinder when the remaining wall of the surface area of the cylinder.
thickness in an area of line or crevice corrosion 3
inches in length or greater is less than 3/4 of the 2. Condemn an aluminum cylinder when the
MADT. depth of isolated pits exceeds 25% of the
minimum cylinder wall thickness.
3. Condemn a steel cylinder when the remaining wall
thickness in an area of line or crevice corrosion less 3. Condemn an aluminum cylinder when the
than 3 inches in length is less than 1/2 of the MADT. deepest pit in an area of line corrosion of less
than 3 inches in length exceeds 25% of mini-
4. Condemn a steel cylinder when the remaining wall mum cylinder wall thickness.
thickness in an area of general corrosion is less than
1/2 of the MADT. 4. Condemn an aluminum cylinder when the
deepest pit in an area of line corrosion more
than 3 inches in length exceeds 15% of mini-
mum cylinder wall thickness.

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.

101
CYLINDER REQUALIFICATION

MINIMUM ALLOWABLE DESIGN THICKNESS FOR LOW PRESSURE CYLINDERS

NOTE: This table is for reference only.

102
LESSON10:SPECIALREQUALIFICATIONCONSIDERATIONSFORCERTAINCYLINDERMATERIALSANDTYPES

REQUALIFY COMPOSITE CYLINDERS


Composite cylinders are made of a composite of
fiberglass and thermoplastic materials. Composite
cylinders are lighter in weight and sufficiently
transparent to allow the user to see the liquid level
inside.

Currently, NFPA 58 states that composite material


cylinders used under a special permit issued by DOT
must be requalified in accordance with the terms of
the permit. 49 CFR is the driving document that issues
the permit for these cylinders.

Specific requirements for the requalification of


composite cylinders are contained in the DOT Special
Permit for that cylinder alone. The requirements
may vary from permit to permit, cylinder to cylinder,
and manufacturer to manufacturer. Always follow
the manufacturer’s instructions pertaining to
requalification. As always consult your supervisor or
fuel supplier and follow your company policy.

103
CYLINDER REQUALIFICATION

REQUALIFY STATIONARY DOT CYLINDERS


As prescribed in NFPA 58, DOT cylinders in stationary
service that are filled on site are required to meet
all of the DOT requirements for requalification with
the exception of verifying tare weight. However, DOT
cylinders requalified while in stationary service are not
authorized for transport in commerce.

When in stationary service, DOT cylinders must


be visually inspected 12 years from the date of
manufacture and every 5 years thereafter as
prescribed in CGA C-6 with the exception of the
requirement of tare weight verification. If any damage
is observed that meets or is more severe than the
rejection limits, the cylinder must be removed from
service permanently. Repair of the cylinder is not
authorized.

When a stationary cylinder passes the requalification


inspection, document the inspection and cylinder
disposition. Then, mark the cylinder with the
inspection date followed by the letter “E.” However,
do not mark the RIN number on the cylinder. A RIN
number is location specific and does not apply when
requalifying cylinders in the field.

In the event a stationary cylinder must be transported


over public roads, red tag and take the cylinder out of
service before transport. In order for the cylinder to
once again be qualified for transport in commerce,
the entire requalification inspection process must
be repeated at the bulk plant, including tare weight
verification. If the cylinder passes the inspection,
document the inspection and cylinder disposition.
Then, mark the cylinder with a new requalification date
followed by the letter “E” along with the facility RIN
number. The cylinder is then considered suitable for
transport in commerce under DOT regulations.

Some states have different compliance requirements.


Talk to your supervisor if you have questions regarding
a permanent cylinder installation that is filled on site.

104
LESSON10:SPECIALREQUALIFICATIONCONSIDERATIONSFORCERTAINCYLINDERMATERIALSANDTYPES

REQUALIFY MOTOR FUEL/FORKLIFT


CYLINDERS
Motor fuel and forklift cylinders are used in liquid –– Cylinders manufactured prior to October 1,
service and may be made of steel, aluminum, or 1998, and designed for use in the horizontal
composite material. For the most part, these cylinders position and where an overfilling prevention
are requalified in accordance with the material used to device is not available.
construct them.
•• Horizontal cylinders exempted from the OPD
Motor fuel cylinders, including those used on forklifts requirement must be marked with a label to
and other industrial machines, are also subject to indicate that they are not equipped with the
some special requirements as defined in NFPA 58: device.
•• All cylinders used in industrial truck service In terms of the requalification inspection for motor
(including forklift truck cylinders) must have the fuel and forklift cylinders, you must keep in mind and
cylinder’s pressure relief valve replaced with a check for the following:
new or unused valve within 12 years of the date
of manufacture of the cylinders and every 10 •• The pressure relief valve must be replaced with
years thereafter. a new one within 12 years of the manufacture
date, and every 10 years after that.
•• An OPD is not required for:
•• These cylinders are not required to have an OPD.
–– Engine fuel cylinders used on industrial The lack of an OPD is not cause to reject these
(and forklift) trucks powered by propane or types of cylinders from requalification.
for engine fuel cylinders used on vehicles
(including floor maintenance machines) •• When an OPD is not present, the cylinder must
having propane powered engines mounted on be labeled to indicate this.
them.
•• Pressure relief valve discharge must be directed
upward within 45 degrees of vertical.

105
CYLINDER REQUALIFICATION

REQUALIFY SMALL ENGINE CYLINDERS


Small engine cylinders often look similar to forklift
cylinders. They are typically made of aluminum and
equipped for vapor service in the horizontal position.
They are currently manufactured to the same DOT 4E
standard as forklift cylinders and should be requalified
as such.

Although these cylinders are manufactured and


requalified under the same specification of forklift
cylinders, they typically have left-hand threads on
male and female safety couplers. These are unique to
this type of cylinder and are not interchangeable with
forklift cylinders.

106
LESSON10:SPECIALREQUALIFICATIONCONSIDERATIONSFORCERTAINCYLINDERMATERIALSANDTYPES

CHECK FOR UNDERSTANDING – SPECIAL REQUALIFICATION CONSIDERATIONS FOR


CERTAIN CYLINDER MATERIALS AND TYPES
Select the appropriate answer for the following question. Check your work on page 126.

NFPA 58 allows composite cylinders to be used for propane service under a special permit issued by DOT.

True

False

107
CYLINDER REQUALIFICATION

108
CYLIN
REQU
LESSON 11: CYLINDER REQUALIFICATION SUMMARY

INTRODUCTION
In this course, you learned how to:

•• Identify DOT requirements for requalifying DOT cylinders.

•• Inspect and requalify, reject, or condemn a cylinder.

•• 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.

109
CYLINDER REQUALIFICATION

REQUIREMENTS FOR REQUALIFYING DOT


CYLINDERS
In the first few lessons, you learned the steps involved
in preparing a DOT cylinder for requalification.

This included:

•• Determining the required requalification date


for the DOT cylinder using the chart of
requalification periods for DOT cylinders.

•• Obtaining a Visual Inspection Report form for


completion.

•• Preparing the cylinder for inspection by


emptying the cylinder; removing any rust, caked
paint, and/or dirt from the cylinder; and marking
e
Exampl
any potential problem areas.

110
LESSON 11: CYLINDER REQUALIFICATION SUMMARY

THE VISUAL INSPECTION PROCEDURE


You went through the visual inspection procedure for requalifying DOT cylinders. The process was broken down
into four major steps: Prepare, Inspect, Leak Test, and Process.

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.

Prepare Inspect Leak Test Process


Verify Fire exposure Leak test Mark (OK) and
requalification return to
date Distortions service

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

111
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 Cylinder distortion Condemn cylinder, mark report SC. YES


If necessary, YES
Refer to the “Resources” section of this manual to view a full page, foldout chart.

empty cylinder more than 1%? Continue to Step 4: Process NO


NO
YES
Perform pre-fill Reject cylinder, mark report RM.
NO Continue to Step 4: Process
inspection to Can/will cylinder be Leak at Threaded opening
determine suitability Cylinder leaning? YES cylinder still leaking after YES Reject cylinder,
Prepare cylinder repaired and requalified*? YES
for continued service for inspection Condemn cylinder, mark report SC. threaded resealing and mark report RM.
NO Continue to
Continue to Step 4: Process opening(s)? retesting for leaks?
Step 4: Process
NO
YES
Damage Reject cylinder, mark report RM.
Continue to NO Continue to Step 4: Process
to valve Can/will cylinder be
Step 2: Inspect YES
openings? repaired and requalified*?
Condemn cylinder, mark report SC. Leak somewhere other Condemn cylinder, mark
YES report SC.
NO Continue to Step 4: Process than a threaded opening?
Continue to Step 4: Process
YES
Reject cylinder, mark report RM.
Damage to NO Continue to Step 4: Process
attachments? YES Can/will cylinder be
repaired and requalified*?
Condemn cylinder, mark report SC.
NO Continue to Step 4: Process
Are any dents:
Significant
YES • on a weld and more than 1/4” deep Condemn cylinder, mark report SC.
dents? YES
NO
• More than 10% deeper than the
greatest diameter of the dent
Continue to Step 4: Process
4: Process
NO
Significant Cylinder has passed Mark cylinder neck
cuts, gouges Are any of the cuts, gouges or digs inspection and YES collar with RIN,
YES Condemn cylinder, mark report SC. report marked OK? next requalification
or digs? outside the LP-Gas Cylinder Damage YES
Continue to Step 4: Process
Limits Table damage limits? date, and letter E
NO
NO
NO
• Note cause of rejection in
Significant isolated Is any of the isolated pitting, Cylinder has been comments section of report
pitting, line or Condemn cylinder, mark report SC. rejected and report YES
YES line or general corrosion outside YES
Continue to Step 4: Process • Mark cylinder part or point
general corrosion? the LP-Gas Cylinder Damage marked RM? that failed inspection with
Limits Table damage limits? NO
paint or waterproof marker
NO
• Repair or send for repairs
NO based on company policy
Has empty cylinder Condemn cylinder, mark report SC*.
lost more than 5% of YES
Continue to Step 4: Process
marked tare weight? Leak is somewhere If necessary, notify the cylinder
other than a YES owner of status. With owners
CYLINDER REQUALIFICATION

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.

112
LESSON 11: CYLINDER REQUALIFICATION SUMMARY

DISPOSITION OF CYLINDERS AFTER INSPECTION


Next, you learned how to record the cylinder disposition appropriately on the inspection report after completing
your inspection. Possible dispositions after inspection include:

•• Return to service – OK.

•• 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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CYLINDER REQUALIFICATION

MARKING CYLINDERS
You learned how to mark the cylinders based on their
disposition after inspection. Cylinders should be
marked by:

•• Stamping.

•• Scribing.

•• Engraving.

•• Other method that produces a legible, durable


mark.

Refer to your company policy or contact your fuel


supplier for more information on the marking method
to use. Typically, the following marking procedures are
used:

•• Cylinders that pass inspection (OK) are


marked with the RIN and the requalification
date followed by the letter “E” before they are
returned to service.

•• Cylinders that are rejected during the inspection


(RM) must be marked with paint or waterproof
marker at the point or points on the cylinder
that caused the rejection.

•• Cylinders that are scrapped/condemned during


the inspection (SC) must be:

–– Stamped with Xs over the DOT specification


number and pressure stamp.

or

–– Stamped with CONDEMNED on the cylinder


neck, top head, or shoulder.

or

–– Rendered incapable of holding pressure.

114
LESSON 11: CYLINDER REQUALIFICATION SUMMARY

SPECIAL REQUIREMENTS FOR CERTAIN


CYLINDER TYPES
Finally, we identified special requirements that apply
to:

•• Aluminum cylinders.

•• Composite cylinders.

•• Stationary cylinders.

•• Motor fuel/Forklift cylinders.

•• Small engine cylinders.

115
CYLINDER REQUALIFICATION

116
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REQU
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?

a. Always place personal and customer safety first.


b. Never place personal safety first.
c. Only place personal safety first if there is no one else around.
d. None of the above.

_________________________________________________________________________________________
2. Which of the following are NOT approved testing methods for DOT cylinder requalification? Select all that
apply:

a. External hydrostatic compression test.


b. Proof pressure test.
c. Water jacket hydrostatic test.
d. External visual inspection.

____________________________________________________________________________________________
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

117
CYLINDER REQUALIFICATION

____________________________________________________________________________________________
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:

a. Add 5% liquid in the cylinder.


b. Gather the required inspection forms.
c. Verify the cylinder date requirements.
d. Prepare the cylinder for inspection.

____________________________________________________________________________________________
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.

118
COURSE QUIZ

________________________________________________________________________________________
8. Match each picture with the type of damage it shows.

______ Dent

A.

______ Attachment damage

B.

______ Fire damage

C.

______ Corrosion

D.

______ Valve damage

E.

F.

G.

119
CYLINDER REQUALIFICATION

____________________________________________________________________________________________
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?

a. Immediately stamp the cylinder CONDEMNED.


b. Verbally notify the cylinder owner that the cylinder is condemned and cannot be filled with hazardous material
and offered for transportation in commerce.
c. Render the cylinder incapable of holding pressure.
d. Notify the cylinder owner in writing that the cylinder is condemned and cannot be filled.

120
COURSE QUIZ

____________________________________________________________________________________________
14. Aluminum cylinders that have been exposed to fire must be:

a. Immediately removed from service, condemned, and scrapped.


b. Rejected and sent for reconditioning.
c. Able to pass inspection in all other areas to continue service.
d. Inspected for visible bulges.

____________________________________________________________________________________________
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:

a. An overfilling prevention device.


b. A vapor service valve.
c. Pressure relief valve.
d. Dip tube.

____________________________________________________________________________________________
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.

121
CYLINDER REQUALIFICATION

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?

a. Continue with the requalification inspection.


b. Condemn the cylinder.
c. Reject the cylinder.
d. Repair the cylinder.

____________________________________________________________________________________________
20. How do you determine the minimum allowable tare weight for a specific cylinder to be requalified?

a. Multiply the marked tare weight by 0.05.


b. Divide the current tare weight by 0.95.
c. Multiply the marked tare weight by 0.95.
d. Divide the marked tare weight by 0.05.

____________________________________________________________________________________________
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.

a. The foot ring


b. A threaded opening
c. The neck collar
d. A weld

____________________________________________________________________________________________
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.

122
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

123
CYLINDER REQUALIFICATION

CERTIFICATE OF TRAINING
Propane Education & Research Council (PERC)

_______________________________has successfully completed the

Cylinder Requalification Training Course

To be filled in by the employee:


This is to certify that on _____________________________, I, _________________________________________
(employee’s signature)

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.

This is to certify that on _______________________________, the above-named employee completed Cylinder


Requalification training. The training materials used to meet the training requirements are available at the
employer’s office.

124
CYLIN
REQU
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

Lesson 5: Check for Understanding –


Requalification Process Overview Lesson 6: Check for Understanding – Prepare for
Match the cylinder requalification task with the Requalification
appropriate part of the cylinder requalification You are using a compressor system to evacuate
process. Some answers are used more than once. the liquid propane from cylinders that need valve
replacement. The scavenging tank has reached the
a. Prepare Determine the cylinder requalification maximum filling level. You turn the compressor off and
date. a. close all valves. What would be the next step to recover
b. Inspect Document and return a requalified what is in the scavenger tank?
cylinder to service. d.
c. Leak Test Obtain a visual inspection report form. C. Reverse the vapor line connections or change the position
a. of the 4-way valve.
d. Process Check the cylinder for fire damage. b.
Charge the cylinder with propane
vapor. c. Lesson 6: Learning Activity – Evacuating
Weigh the empty cylinder. b.
Cylinders
Remove only the liquid propane from a cylinder. b. Differential
pressure (gravity method).

Frequently called a scavenging system. (1). c. Compressor


system.

Know where the emergency shutdowns and fire extinguishers


are located. a. All

Wear the appropriate PPE. a. All

125
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.

You are requalifying a cylinder and are at the point of


inspecting for fire damage. Mark the items in the list
below that may indicate there is fire damage. Lesson 7: Check for Understanding – Perform an
Inspection on a Steel Cylinder
b. Hand wheel is warped, d. Blue-black discoloration on the
metal, e. Bubbled container coating. A cylinder that has lost more than ________% of its
marked tare weight should be condemned.
b. 5
Lesson 7: Check for Understanding – Perform an
Inspection on a Steel Cylinder
The term ‘neck’ refers to the _______________ opening Lesson 9: Check for Understanding – Process the
in cylinders that contain only one top opening or Cylinder
service end. If, after inspection, a cylinder needs to be rejected and
a. service valve sent for repairs before returning it to service, which of
the following items is NOT part of the process to reject
the cylinder?
Lesson 7: Check for Understanding – Perform an b. Render the cylinder incapable of holding pressure.
Inspection on a Steel Cylinder
To inspect the cylinder foot ring or supports, you must
________________. Lesson 10: Check for Understanding – Special
Requalification Considerations for Certain
c. invert the cylinder. Cylinder Materials and Types
NFPA 58 allows composite cylinders to be used for
Lesson 7: Learning Activity – Requalification of propane service under a special permit issued by DOT.
DOT Cylinders
a. True
1. No.

2. Yes.

3. No.

126
CYLIN
REQU
RESOURCES

CONTENTS
Pressure Measurements

How to Chase (Clean or Repair) Threads

Reasons Pressure Relief Valves Open

Repair Service Valve Considerations

Container Marker Requirements

Visual Inspection Method Application

127
CYLINDER REQUALIFICATION

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.

Gauge Pressure - psig


In most industrial applications, we are concerned with the pressure inside a container or piping system, and
how hard the stuff inside is pushing to get out. What matters is how the pressure inside the container or piping
system compares with the surrounding air 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.

128
RESOURCES

HOW TO CHASE (CLEAN OR REPAIR) THREADS


Apply a drop or two of lubricant to the tap existing threads. The lubricant helps minimize friction and prevents
the threads from tearing as they are chasedtapped. But, do not allow the lubricant to contaminate the
container. Turn the tap by hand at least two full threads. Then use a T- handle tap wrench to turn the tap
clockwise until you feel resistance. When you feel resistance, reverse direction one full turn to clear and break
any chip produced from the tapping operation. If the pipe tap binds up, remove the tap. Do not force the tap!
Continue until the tap is engaged fully into the female thread. When finished, wipe off the threads with a clean
cloth and solvent to remove any cutting oil before installing the valve.

129
CYLINDER REQUALIFICATION

REASONS PRESSURE RELIEF VALVES OPEN


At times, pressure relief valves may open due to one of the following:

•• 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.

•• Valve malfunction: springs break, age, deterioration of valve, etc.

•• Incorrect application - relief valve that is not correct for the intended use

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RESOURCES

REPAIR SERVICE VALVE CONSIDERATIONS


Is this valve field serviceable? Packing or gland nuts are either right-hand or left-hand threaded. Before
removing the packing nut, always ensure that the gland nut is loosened in the correct direction. Remember,
left-handed threads are indicated by a “V” notched in the packing nut.

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.

CONTAINER MARKER REQUIREMENTS

131
CYLINDER REQUALIFICATION

VISUAL INSPECTION METHOD APPLICATION


The form is also available for download on the Pipeline and Hazardous Materials Safety Administration website.
http://www.phmsa.dot.gov/

Application for Facility Registration to Requalify


Cylinders by Visual Inspection Method Only
___New Application ___Renewal Application ___Modification Current RIN#________

Application made in accordance with requirements of 49 CFR Part 107.805(f)


Company Name: _______________________________________________________________
(If you are a company that is doing business as (dba), use the following format, corporate name dba company name)

Facility Manager Name: __________________________________________________________________

Facility Address: (where visual inspections will be performed)


______________________________________________________________________________________
Street
______________________________________________________________________________________
City State Zip Code

Facility Telephone:_____________________________ Fax_________________________


Email:________________________________________

Mailing Address: ________________ Corporate_______________

Company Name: ________________________________________________________________________


______________________________________________________________________________________
Street
_______________________________________________________________________________________
City State Zip Code
Contact Telephone:___________________________ Email: ___ ____________________________

Check DOT Specification/Special Permit Cylinders to be inspected in accordance with 180.209(g):


_____3A _____4B _____4AA480
_____3AA _____4BA _____4B240
_____3A480X _____4BW _____4BW240
_____3B _____4E _____Special Permit (List)_________________________________

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

132
RESOURCES

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.

133
CYLINDER REQUALIFICATION

www.propanecouncil.org | www.propane.com
©2017 Propane Education & Research Council | PRC 003510

134

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