SIST EN 1440:2016
(Main)LPG equipment and accessories - Transportable refillable traditional welded and brazed steel Liquefied Petroleum Gas (LPG) cylinders - Periodic inspection
LPG equipment and accessories - Transportable refillable traditional welded and brazed steel Liquefied Petroleum Gas (LPG) cylinders - Periodic inspection
This European Standard specifies procedures for periodic inspection and testing, for transportable refillable LPG cylinders with a water capacity from 0,5 l up to and including 150 l.
This European Standard is applicable to welded and brazed steel LPG cylinders with a specified minimum wall thickness designed according to EN 1442, EN 12807, EN 13322-1, Council Directive 84/527/EEC Annex I - Parts 1 to 3 or equivalent standard (e.g. national codes).
This European Standard is intended to be applied to cylinders complying with RID/ADR (including pi marked cylinders) and also to existing non RID/ADR cylinder populations.
This European Standard does not apply to cylinders permanently installed in vehicles.
Flüssiggas-Geräte und Ausrüstungsteile - Ortsbewegliche, wiederbefüllbare, geschweißte und hartgelötete Flaschen aus Stahl für Flüssiggas (LPG) - Wiederkehrende Inspektion
Diese Europäische Norm legt Verfahren für die wiederkehrende Inspektion von ortsbeweglichen, wiederbefüll-baren Flaschen für Flüssiggas (LPG) mit einem Fassungsraum von 0,5 l bis einschließlich 150 l fest.
Diese Europäische Norm gilt für geschweißte und hartgelötete Flaschen aus Stahl für Flüssiggas (LPG) mit einer festgelegten Mindestwanddicke nach EN 1442, EN 12807, EN 13322 1 sowie Anhang I, Teile 1 bis 3 der Richtlinie des Rates 84/527/EWG oder einer gleichwertigen Norm (z. B. nationale Vorschriften).
Diese Europäische Norm ist für Flaschen anzuwenden, die der/dem RID/ADR entsprechen (einschließlich Flaschen mit Pi Kennzeichnung) sowie für bestehende Flaschengruppen, die nicht der/dem RID/ADR entsprechen.
Diese Europäische Norm gilt nicht für Flaschen, die dauerhaft in Fahrzeugen eingebaut sind.
Equipements pour GPL et leurs accessoires - Bouteilles de gaz de pétrole liquéfiés (GPL) en acier soudé et brasé transportables et rechargeables - Contrôle périodique
Cette Norme européenne spécifie des modes opératoires pour des contrôles et des essais périodiques pour des bouteilles pour GPL transportables et rechargeables d’une capacité en eau comprise entre 0,5 et 150 l.
La présente Norme européenne s’applique aux bouteilles en acier soudé et brasé pour GPL avec une épaisseur de paroi minimale conçue conformément à l’EN 1442, EN 12807, EN 13322-1, à la Directive du Conseil 84/527/CEE, Annexe I, parties 1 à 3 ou à une norme équivalente (par exemple, les codes nationaux).
Il est prévu d’appliquer la présente Norme européenne à des bouteilles conformes au RID/ADR (Règlement concernant le transport international ferroviaire des marchandises dangereuses/Accord européen relatif au transport international des marchandises dangereuses par route) (y compris les bouteilles comportant un marquage pi), ainsi qu’aux familles de bouteilles existantes non-conformes au RID/ADR.
La présente Norme européenne ne s’applique pas aux bouteilles installées en permanence dans des véhicules.
Oprema in pribor za utekočinjeni naftni plin (UNP) - Premične, ponovno polnljive, varjene in trdo spajkane jeklenke za UNP - Periodična kontrola
Ta evropski standard določa postopke za periodične preglede in preskušanje premičnih, ponovno polnljivih jeklenk za utekočinjeni naftni plin (LPG) z vodno kapaciteto od 0,5 l do vključno 150 l.
Ta evropski standard se uporablja za varjene in trdo spajkane jeklenke za LPG z določeno minimalno debelino stene, ki so zasnovane v skladu s standardi EN 1442, EN 12807 in EN 13322-1, z Direktivo Sveta 84/527/EGS (Priloga 1, 1.–3. del) ali z enakovrednim standardom (npr. nacionalni kodeks).
Ta evropski standard se uporablja za jeklenke v skladu z določbami RID/ADR (vključno z jeklenkami z oznako pi) in za obstoječe jeklenke, ki niso v skladu z določbami RID/ADR.
Ta evropski standard se ne uporablja za jeklenke, trajno nameščene v vozila.
General Information
Relations
Standards Content (Sample)
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Flüssiggas-Geräte und Ausrüstungsteile - Ortsbewegliche, wiederbefüllbare, geschweißte und hartgelötete Flaschen aus Stahl für Flüssiggas (LPG) - Wiederkehrende InspektionEquipements pour GPL et leurs accessoires - Bouteilles de gaz de pétrole liquéfiés (GPL) en acier soudé et brasé transportables et rechargeables - Contrôle périodiqueLPG equipment and accessories - Transportable refillable traditional welded and brazed steel Liquefied Petroleum Gas (LPG) cylinders - Periodic inspection23.020.35Plinske jeklenkeGas cylindersICS:Ta slovenski standard je istoveten z:EN 1440:2016SIST EN 1440:2016en,fr,de01-junij-2016SIST EN 1440:2016SLOVENSKI
STANDARDSIST EN 1440:2008+A1:20121DGRPHãþD
SIST EN 1440:2016
EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM
EN 1440
February
t r s x ICS
t uä r t rä u r Supersedes EN
s v v rã t r r z ªA sã t r s tEnglish Version
LPG equipment and accessories æ Transportable refillable traditional welded and brazed steel Liquefied Petroleum Equipements pour GPL et leurs accessoires æ Bouteilles transportables et rechargeables æ Contrôle pßriodique FlüssiggasæGeräte und Ausrüstungsteile æ Ortsbeweglicheá wiederbefüllbareá herkömmlich geschweißte und hartgelötete Flaschen aus Stahl für This European Standard was approved by CEN on
s u December
t r s wä
egulations which stipulate the conditions for giving this European Standard the status of a national standard without any alterationä Upætoædate lists and bibliographical references concerning such national standards may be obtained on application to the CENæCENELEC Management Centre or to any CEN memberä
translation under the responsibility of a CEN member into its own language and notified to the CENæCENELEC Management Centre has the same status as the official versionsä
CEN members are the national standards bodies of Austriaá Belgiumá Bulgariaá Croatiaá Cyprusá Czech Republicá Denmarká Estoniaá Finlandá Former Yugoslav Republic of Macedoniaá Franceá Germanyá Greeceá Hungaryá Icelandá Irelandá Italyá Latviaá Lithuaniaá Luxembourgá Maltaá Netherlandsá Norwayá Polandá Portugalá Romaniaá Slovakiaá Sloveniaá Spainá Swedená Switzerlandá Turkey andUnited Kingdomä
EUROPEAN COMMITTEE FOR STANDARDIZATION COMITÉ EUROPÉEN DE NORMALISATION EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre:
Avenue Marnix 17,
B-1000 Brussels
9
t r s x CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Membersä Refä Noä EN
s v v rã t r s x ESIST EN 1440:2016
EN 1440:2016 (E) 2 Contents Page European foreword . 4 Introduction . 5 1 Scope . 6 2 Normative references . 6 3 Terms and definitions . 7 4 Requirements for periodic inspection . 7 Table 1 — Requirements for periodic inspection . 8 5 Inspections and tests . 9 5.1 General . 9 5.2 External visual inspection . 9 5.2.1 Preparation for external visual inspection. 9 5.2.2 Inspection procedure . 9 5.2.3 Rejection criteria . 10 5.3 Proof pressure test . 10 5.3.1 General . 10 5.3.2 Hydraulic proof pressure test. 10 5.3.3 Pneumatic proof test and leak test . 11 5.4 Check of the internal condition of the cylinder . 12 5.4.1 Check of the internal condition of welded steel cylinders . 12 5.5 Inspection of cylinder threads . 13 5.5.1 General . 13 5.5.2 Internal threads . 13 5.5.3 External threads . 13 5.5.4 Damaged threads . 13 5.6 Inspection of valves . 13 6 Final operations . 13 6.1 General . 13 6.2 Valving . 13 6.3 Tare mass . 14 6.4 Marking . 14 6.5 Purging . 14 7 Repair of welded steel cylinders . 14 7.1 Major repairs . 14 7.2 Minor repairs . 14 7.3 Requirements for repair . 14 8 Records . 15 Annex A (normative)
Specific requirements for external visual inspection . 16 Table A.1 — Physical defects in the cylinder wall . 16 Table A.2 — Corrosion on the cylinder wall . 17 Table A.3 — Other defects . 18 SIST EN 1440:2016
EN 1440:2016 (E) 3 Annex B (informative)
Requirements for 15 year periodic inspection interval for cylinders manufactured before January 1st 2015 . 19 B.1 General . 19 B.2 Concept of control. 19 B.3 Conditions . 20 Annex C (normative)
Periodic inspection procedure for cylinder populations not covered by the RID/ADR . 21 Table C.1 — Procedures for periodic inspection . 21 Annex D (informative)
Requirements to be fulfilled to extend period between two periodic inspections to 15 years for RID/ADR welded steel LPG cylinders . 22 D.1 General . 22 D.2 Design and manufacturing . 22 D.3 Operational provisions . 22 D.4 Periodic inspection . 22 D.5 Marking . 23 Annex E (informative)
Alternative test applicable to commercial butane cylinders with less than 6,5 l water capacity . 24 E.1 General . 24 E.2 Preparation of cylinder . 24 E.3 Procedure . 24 Bibliography . 25
SIST EN 1440:2016
EN 1440:2016 (E) 4 European foreword This document (EN 1440:2016) has been prepared by Technical Committee CEN/TC 286 “Liquefied petroleum gas equipment and accessories”, the secretariat of which is held by NSAI. This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by August 2016, and conflicting national standards shall be withdrawn at the latest by August 2016. Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent rights. This document in conjunction with EN 16728:20161 supersedes EN 1440:2008+A1:2012. This European Standard has been submitted for reference into the RID [1] and the technical annexes of the ADR [2]. NOTE These regulations take precedence over any clause of this standard. It is emphasized that RID/ADR are being revised regularly at intervals of two years which may lead to temporary non- compliances with the clauses of this standard. This European Standard deals with the periodic inspection requirements for transportable refillable welded and brazed steel LPG cylinders. For all other cylinder designs, EN 16728:20161 applies. According to the CEN-CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom.
1 To be published in 2016. SIST EN 1440:2016
EN 1440:2016 (E) 5 Introduction The primary objective of the periodic inspection of transportable refillable liquefied petroleum gas (LPG) cylinders is that, on completion of the tests, the cylinders can be re-introduced into service for a further period of time. The very large populations of traditional steel LPG cylinders in use have led to the development of alternative methods of inspection. This European Standard has been prepared to reflect the current methodology for periodic inspection of LPG cylinders and is based on extensive operating experience. This European Standard calls for the use of substances and procedures that can be injurious to health if adequate precautions are not taken. It refers only to technical suitability and does not absolve the user from legal obligations relating to health and safety, at any stage. Protection of the environment is a key political issue in Europe and elsewhere, for CEN/TC 286 this is covered in CEN/TS 16765 [3], and this Technical Specification should be read in conjunction with this standard. It has been assumed in the drafting of this European Standard that the execution of its provisions is entrusted to appropriately qualified and competent persons. Where judgements are called for, it has been assumed that they are made by competent persons who have been specifically trained for the tasks. SIST EN 1440:2016
EN 1440:2016 (E) 6 1 Scope This European Standard specifies procedures for the periodic inspection and testing, of transportable refillable LPG cylinders with a water capacity from 0,5 l up to and including 150 l. This European Standard is applicable to welded and brazed steel LPG cylinders with a specified minimum wall thickness designed according to EN 1442, EN 12807, EN 13322-1, or equivalent standard (e.g. national codes). This European Standard is intended to be applied to cylinders complying with RID/ADR (including pi marked cylinders) and also to existing non RID/ADR cylinder populations. NOTE The requirements of RID/ADR take precedence over those of this standard in the case of cylinders complying with that regulation, including pi marked cylinders. This European Standard does not apply to cylinders permanently installed in vehicles. 2 Normative references The following documents, in whole or in part, are normatively referenced in this document and are indispensable for its application. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 837-1:1996, Pressure gauges - Part 1: Bourdon tube pressure gauges - Dimensions, metrology, requirements and testing EN 837-3:1996, Pressure gauges - Part 3: Diaphragm and capsule pressure gauges - Dimensions, metrology, requirements and testing EN 1442, LPG equipment and accessories — Transportable refillable welded steel cylinders for LPG — Design and construction EN 12807, LPG equipment and accessories - Transportable refillable brazed steel cylinders for liquefied petroleum gas (LPG) - Design and construction EN 12816, LPG equipment and accessories - Transportable refillable LPG cylinders - Disposal EN 13322-1, Transportable gas cylinders - Refillable welded steel gas cylinders - Design and construction - Part 1: Carbon steel EN 14894, LPG equipment and accessories - Cylinder and drum marking EN 14912, LPG equipment and accessories - Inspection and maintenance of LPG cylinder valves at time of periodic inspection of cylinders EN ISO 14245, Gas cylinders - Specifications and testing of LPG cylinder valves - Self-closing (ISO 14245) EN ISO 15995, Gas cylinders - Specifications and testing of LPG cylinder valves - Manually operated (ISO 15995) SIST EN 1440:2016
EN 1440:2016 (E) 7 3 Terms and definitions For the purposes of this document, the following terms and definitions apply. 3.1 competent authority authority or authorities or any other body or bodies designated as such in each State and in each specific case in accordance with domestic law 3.2 competent person person which by combination of appropriate qualification, training, experience, and resources, is able to make objective judgments on the subject 3.3 inspection body independent inspection and testing body approved by the competent authority 3.4 Liquefied Petroleum Gas LPG low pressure liquefied gas composed of one or more light hydrocarbons which are assigned to UN 1011, UN 1075, UN 1965, UN 1969 or UN 1978 only and which consists mainly of propane, propene, butane, butane isomers, butene with traces of other hydrocarbon gases 3.5 periodic inspection activities carried out at defined intervals, such as examining, measuring, testing or gauging the characteristics of a pressure vessel and comparing these with specified requirements 3.6 tare mass sum of the mass of the empty cylinder, the mass of the valve including a dip tube where fitted, and the mass of all other parts that are permanently attached to the cylinder when it is being filled, e.g. fixed valve guard 4 Requirements for periodic inspection The interval between periodic inspections shall be dependent on the content of a written scheme. NOTE 1 A written scheme describes work procedures, criteria, responsibilities and other minimum requirements. The maximum interval between periodic inspections for LPG cylinders shall be 10 years; however it can be extended to 15 years under the following conditions: — for LPG cylinders manufactured before the date 2015-01-01, provided the conditions of Annex B are fully met and approval from the relevant competent authority(ies) has been given; and — for RID/ADR welded steel LPG cylinders, provided the requirements of Annex D are fulfilled and approval from the competent authority has been given. Periodic inspections/tests shall be carried out by a competent person under the authorization of an inspection body based on a written scheme and in accordance with the requirements specified in Table 1. SIST EN 1440:2016
EN 1440:2016 (E) 8 NOTE 2 RID [1] and ADR [2] include detailed requirements on the qualification, obligations, accreditation and approval of these inspection bodies. Cylinders rejected shall be segregated and shall be either reconditioned, re-tested or rendered unserviceable. The decision to render a cylinder unserviceable can be taken at any stage during the periodic inspection procedure. With agreement by the owner, a cylinder shall be rendered unserviceable in accordance with EN 12816 such that it cannot be re-issued into service as a pressure vessel. NOTE 3 In some countries render unserviceable means scrapping. NOTE 4 With the agreement of the competent authority, the proof pressure test of cylinders can be replaced by an equivalent method based on acoustic emission testing, ultrasonic examination or a combination of acoustic emission testing and ultrasonic examination. EN ISO 16148 [4] can be used as a guide for acoustic emission testing procedures. NOTE 5 Tests can be performed in any order as determined by the written scheme. Table 1 — Requirements for periodic inspection Cylinder types Maximum periodic inspection interval Tests Brazed steel cylinders in conformance with EN 12807 or equivalent standard. 10 years — External visual inspection as described in 5.1. and Annex A; — Proof pressure test (hydraulic proof pressure test or, with the agreement of the competent authority, a pneumatic proof test followed by a leak test) as described in 5.2; — Internal condition check as described in 5.3 and Annex A; — Inspection of threads as described in 5.4; — Inspection of valves as described in 5.5. Welded steel cylinders in conformance with EN 1442, EN 13322–1 or equivalent standard (e.g. national codes). — 10 years; or — 15 years under the conditions of Annex B (cylinders manufactured before 1st January 2015); or — 15 years under the conditions of Annex D. Welded steel cylinders with a water capacity of less than 6.5 l. 10 years As for welded steel cylinders in conformance with EN 1442 (see above), or with the agreement of the competent authority, as specified in Annex E. Non RID/ADR welded and brazed steel cylinders. As determined by the competent authority. As specified in Annex C. SIST EN 1440:2016
EN 1440:2016 (E) 9 5 Inspections and tests 5.1 General Relevant cylinder data shall be identified before any inspections or tests are carried out. Cylinders which cannot be safely emptied of gas shall be set aside for special handling. Cylinders with inoperative or blocked valves shall be set aside for safe valve removal. Before preparing for inspection, manufacturer's guidelines shall be taken into account to avoid any damage to the cylinders. Any chemical solutions and/or cleaning methods used shall be selected to ensure that they do not adversely affect cylinder material. 5.2 External visual inspection 5.2.1 Preparation for external visual inspection a) If necessary, the cylinder shall be cleaned and have all loose coatings or labels, corrosion products, tar, oil or other foreign matter removed from its external surface, b) Care shall be taken to avoid damaging the cylinder, c) When cylinders are treated by a process that might remove cylinder material, the inspection body shall decide whether a thickness test is required, e.g. ultrasonic thickness check. NOTE Cleaning methods include wire brushing, shot blasting (in accordance with EN ISO 8504 [6] series and EN ISO 8501-1 [5]), water jet cleaning, chemical cleaning or other suitable methods, that do not adversely affect any part of the cylinders. 5.2.2 Inspection procedure LPG cylinders shall be inspected for: a) dents, cuts, gouges, bulges, cracks, laminations or punctures while applying the criteria for rejection in Annex A; b) corrosion, applying the criteria for rejection given in Annex A; while giving special attention to areas where water can be trapped EXAMPLE at the base of the cylinder; the junction between the cylindrical shell and the foot-ring; the junction between the cylindrical shell and the valve guard or shroud; and hidden corrosion (e.g. under handles). c) other defects (e.g. depressed bung or fire damage) while applying the criteria for rejection given in Annex A; d) integrity of all permanent attachments; and e) integrity of all mandatory permanent markings. SIST EN 1440:2016
EN 1440:2016 (E) 10 5.2.3 Rejection criteria The specific requirements for external visual inspection of LPG cylinders are described in Annex A including defect descriptions and rejection limits. 5.3 Proof pressure test 5.3.1 General The test shall consist of one of the proof pressure tests described in 5.3.2 and 5.3.3. Proof pressure testing, according to 5.3.3, requires the agreement of a competent authority. The pneumatic proof test as described in 5.3.3 shall only be implemented where such an operation does not entail any danger. Pressure gauges that are used to read the cylinder test pressure, shall be in accordance with EN 837-1:1996 and EN 837-3:1996, accuracy class 1,6 or better. They shall be calibrated or checked for accuracy against a master gauge at regular intervals and not less frequently than once every six months. The master gauge shall be re-calibrated in accordance with national requirements. All joints within the system shall be leak tight. The test equipment shall not restrict the expansion of the cylinder. 5.3.2 Hydraulic proof pressure test 5.3.2.1 General A non-corrosive liquid that is compatible with the material of construction of the cylinder shall be used as the test medium. 5.3.2.2 Preparation of cylinders a) Cylinders shall be depressurized in a safe and controlled manner before proceeding. b) The external surface of the cylinder shall be in such a condition that any leak can be detected. If the cleaning method involves the wetting of the outside surface or if the outside surface is wet due to outdoor storage conditions, the outside surface shall be completely dried before commencing the test procedure. 5.3.2.3 Test equipment The design and installation of the equipment and the cylinders connected to it shall ensure that no air is trapped in the system. A device shall be fitted to the test equipment to ensure that no cylinder is subjected to pressure in excess of its test pressure by more than the tolerance given in 5.3.2.4. 5.3.2.4 Test procedure a) The cylinder shall be positioned so that the welds are visible during the test. b) The test pressure for a RID/ADR cylinder shall be at least the test pressure marked on the cylinder. For non-RID/ADR cylinders see Annex C. c) The pressure shall be gradually increased in the cylinder until the test pressure is reached. d) The test pressure shall not be exceeded by more than 20 % or 6 bar, whichever is the least. More than one cylinder can be tested at a time provided they all have a test pressure within the tolerance specified. If the cylinder is tested at a higher pressure than that marked, the owner of the cylinder shall calculate the maximum pressure not to be exceeded to ensure that the general membrane SIST EN 1440:2016
EN 1440:2016 (E) 11 stress in the cylinder wall does not exceed 90 % of the guaranteed minimum yield strength of the material used in the finished cylinder. NOTE This can be demonstrated by the following formula: ()−≤×0,920hoPDeRe (1) where Ph actual test pressure applied to the cylinder by the manufacturer, in bar. D outside diameter of the cylinder, in millimetres e actual thickness of the material in the finished cylinder (at the point under consideration), in millimetres R0 minimum value of yield strength guaranteed by the cylinder manufacturer for the finished cylinder, in newton's per square millimetre e) Test pressure shall be held for the time necessary to inspect the cylinder and check it out for any leak and/or other defects, but not less than 15 s. f) If there is leakage in the pressure system, it shall be corrected and the cylinders re-tested. g) Cylinders, that do not leak or show any visible permanent distortion after the pressure has been released, shall be deemed to have passed this test. Cylinders showing visible defects shall be examined by a competent person. h) Cylinders that fail this test shall be rejected. i) Records of rejected cylinders shall be maintained. 5.3.3 Pneumatic proof test and leak test 5.3.3.1 Preparation of cylinders a) If cylinders have to be depressurized, it shall be carried out in a safe and controlled manner before proceeding. b) Repainting before the pneumatic test shall be limited to a primer coat. The finishing coat shall be applied after the test in order not to mask potential leaks. NOTE The valve can be fitted before the proof test or leak test, see 6.2. 5.3.3.2 Procedure 5.3.3.2.1 Proof test a) Cylinders shall be tested in a safe enclosure to protect against rupture under pneumatic pressure. Adequate safety procedures and measures (e.g. hearing protection) shall be adopted to protect personnel in charge of the test. b) The test pressure for a RID/ADR cylinder shall be at least the test pressure marked on the cylinder. For non-RID/ADR cylinders see Annex C. c) Where a separate pressure relief valve is fitted, an adequate margin of safety shall be maintained between the pneumatic proof test pressure and the pressure setting of the pressure relief valve. Where necessary, the pressure relief valve shall be removed and the port plugged for testing. SIST EN 1440:2016
EN 1440:2016 (E) 12 d) After the cylinder has been placed in a safe enclosure, it shall be charged with the pneumatic test medium (e.g. air, nitrogen) to the test pressure and held at that pressure for at least 5 s. The gas to be used for testing shall be non-flammable to avoid any risk of internal explosion. The cylinder shall pass the proof test if it does not burst. The cylinder shall then be isolated from the pressure source. NOTE Care needs to be taken to avoid corrosion if full water immersion is used. 5.3.3.2.2 Leak test a)
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2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.HJOHGFlüssiggas-Geräte und Ausrüstungsteile - Ortsbewegliche, wiederbefüllbare, geschweißte und hartgelötete Flaschen aus Stahl für Flüssiggas (LPG) - Wiederkehrende InspektionEquipements pour GPL et leurs accessoires - Bouteilles de gaz de pétrole liquéfiés (GPL) en acier soudé et brasé transportables et rechargeables - Contrôle périodiqueLPG equipment and accessories - Transportable refillable traditional welded and brazed steel Liquefied Petroleum Gas (LPG) cylinders - Periodic inspection23.020.30MHNOHQNHPressure vessels, gas cylindersICS:Ta slovenski standard je istoveten z:FprEN 1440kSIST FprEN 1440:2015en,fr,de01-november-2015kSIST FprEN 1440:2015SLOVENSKI
STANDARD
kSIST FprEN 1440:2015
EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM
FINAL DRAFT
FprEN 1440
September
t r s w ICS
t uä r t rä u r Will supersede EN
s v v rã t r r z ªA sã t r s tEnglish Version
LPG equipment and accessories æ Transportable refillable traditional welded and brazed steel Liquefied Petroleum Equipements pour GPL et leurs accessoires æ Bouteilles transportables et rechargeables æ Contrôle pßriodique FlüssiggasæGeräte und Ausrüstungsteile æ Ortsbeweglicheá wiederbefüllbareá herkömmlich geschweißte und hartgelötete Flaschen aus Stahl für This draft European Standard is submitted to CEN members for formal voteä It has been drawn up by the Technical Committee
If this draft becomes a European Standardá CEN members are bounwhich stipulate the conditions for giving this European Standard the status of a national standard without any alterationä
This draft European Standard was established by CEN in three ofer language made by translation under the responsibility of a CEN member into its own language and notified to the CENæCENELEC Management Centre has the same status as the official versionsä
CEN members are the national standards bodies of Austriaá Belgiumá Bulgariaá Croatiaá Cyprusá Czech Republicá Denmarká Estoniaá Finlandá Former Yugoslav Republic of Macedoniaá Franceá Germanyá Greeceá Hungaryá Icelandá Irelandá Italyá Latviaá Lithuaniaá Luxembourgá Maltaá Netherlandsá Norwayá Polandá Portugalá Romaniaá Slovakiaá Sloveniaá Spainá Swedená Switzerlandá Turkey andUnited Kingdomä
Recipients of this draft are invited to submitá with their commentsá notification of any relevant patent rights of which they are aware and to provide supporting documentationä
Warning ã This document is not a European Standardä It is distributed for review and commentsä It is subject to change without notice and shall not be referred to as a European Standardä
EUROPEAN COMMITTEE FOR STANDARDIZATION COMITÉ EUROPÉEN DE NORMALISATION EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre:
Avenue Marnix 17,
B-1000 Brussels
9
t r s w CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Membersä Refä Noä FprEN
s v v rã t r s w EkSIST FprEN 1440:2015
FprEN 1440:2015 (E) 2 Contents Page
European foreword . 4 Introduction . 5 1 Scope . 6 2 Normative references . 6 3 Terms and definitions . 7 4 Requirements for periodic inspection . 7 5 Inspections and tests . 9 5.1 General . 9 5.2 External visual inspection . 9 5.2.1 Preparation for external visual inspection. 9 5.2.2 Inspection procedure . 10 5.2.3 Rejection criteria . 10 5.3 Proof pressure test . 10 5.3.1 General . 10 5.3.2 Hydraulic proof pressure test. 10 5.3.3 Pneumatic proof test and leak test . 12 5.4 Check of the internal condition of the cylinder . 13 5.4.1 Check of the internal condition of welded steel cylinders . 13 5.5 Inspection of cylinder threads . 13 5.5.1 General . 13 5.5.2 Internal threads . 13 5.5.3 External threads . 13 5.5.4 Damaged threads . 14 5.6 Inspection of valves . 14 6 Final operations . 14 6.1 General . 14 6.2 Valving . 14 6.3 Tare mass . 14 6.4 Marking . 14 6.5 Purging . 14 7 Repair of welded steel cylinders . 15 7.1 Major repairs . 15 7.2 Minor repairs . 15 7.3 Requirements for repair . 15 8 Records . 15 Annex A (normative)
Specific requirements for external visual inspection . 16 Annex B (informative)
Requirements for 15 year periodic inspection interval for cylinders manufactured before January 1st 2015 . 19 B.1 General . 19 B.2 Concept of control . 19 kSIST FprEN 1440:2015
FprEN 1440:2015 (E) 3 B.3 Conditions . 20 Annex C (normative)
Periodic inspection procedure for cylinder populations not covered by the RID/ADR . 21 Annex D (informative)
Requirements to be fulfilled to extend period between two periodic inspections to 15 years for RID/ADR welded steel LPG cylinders . 22 D.1 General . 22 D.2 Design and manufacturing . 22 D.3 Operational provisions . 22 D.4 Periodic inspection . 22 D.5 Marking . 23 Annex E (informative)
Alternative test applicable to commercial butane cylinders with less than 6,5 l water capacity . 24 E.1 General . 24 E.2 Preparation of cylinder . 24 E.3 Procedure . 24 Bibliography . 26
kSIST FprEN 1440:2015
FprEN 1440:2015 (E) 4 European foreword This document (FprEN 1440:2015) has been prepared by Technical Committee CEN/TC 286 “Liquefied petroleum gas equipment and accessories”, the secretariat of which is held by NSAI. This document is currently submitted to the Formal Vote. This document in conjunction with FprEN 16728:2015 will supersede EN 1440:2008+A1:2012. This European Standard has been submitted for reference into the RID [1] and the technical annexes of the ADR [2]. NOTE These regulations take precedence over any clause of this standard. It is emphasized that RID/ADR are being revised regularly at intervals of two years which may lead to temporary non- compliances with the clauses of this standard. This European Standard deals with the periodic inspection requirements for transportable refillable welded and brazed steel LPG cylinders. For all other cylinder designs, FprEN 16728:2015 applies. kSIST FprEN 1440:2015
FprEN 1440:2015 (E) 5 Introduction The primary objective of the periodic inspection of transportable refillable liquefied petroleum gas (LPG) cylinders is that, on completion of the tests, the cylinders can be re-introduced into service for a further period of time. The very large populations of traditional steel LPG cylinders in use have led to the development of alternative methods of inspection. This European Standard has been prepared to reflect the current methodology for periodic inspection of LPG cylinders and is based on extensive operating experience. This European Standard calls for the use of substances and procedures that can be injurious to health if adequate precautions are not taken. It refers only to technical suitability and does not absolve the user from legal obligations relating to health and safety, at any stage. Protection of the environment is a key political issue in Europe and elsewhere, for CEN/TC 286 this is covered in CEN/TS 16765 [3], and this Technical Specification should be read in conjunction with this standard. It has been assumed in the drafting of this European Standard that the execution of its provisions is entrusted to appropriately qualified and competent persons. Where judgements are called for, it has been assumed that they are made by competent persons who have been specifically trained for the tasks. kSIST FprEN 1440:2015
FprEN 1440:2015 (E) 6 1 Scope This European Standard specifies procedures for the periodic inspection and testing, of transportable refillable LPG cylinders with a water capacity from 0,5 l up to and including 150 l. This European Standard is applicable to welded and brazed steel LPG cylinders with a specified minimum wall thickness designed according to EN 1442, EN 12807, EN 13322-1, or equivalent standard (e.g. national codes). This European Standard is intended to be applied to cylinders complying with RID/ADR (including pi marked cylinders) and also to existing non RID/ADR cylinder populations. NOTE The requirements of RID/ADR take precedence over those of this standard in the case of cylinders complying with that regulation, including pi marked cylinders. This European Standard does not apply to cylinders permanently installed in vehicles. 2 Normative references The following documents, in whole or in part, are normatively referenced in this document and are indispensable for its application. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 837-1:1996, Pressure gauges - Part 1: Bourdon tube pressure gauges - Dimensions, metrology, requirements and testing EN 837-3:1996, Pressure gauges - Part 3: Diaphragm and capsule pressure gauges - Dimensions, metrology, requirements and testing EN 1442, LPG equipment and accessories — Transportable refillable welded steel cylinders for LPG — Design and construction EN 12807, LPG equipment and accessories - Transportable refillable brazed steel cylinders for liquefied petroleum gas (LPG) - Design and construction EN 12816, LPG equipment and accessories - Transportable refillable LPG cylinders - Disposal EN 13322-1, Transportable gas cylinders - Refillable welded steel gas cylinders - Design and construction - Part 1: Carbon steel EN 14894, LPG equipment and accessories - Cylinder and drum marking EN 14912, LPG equipment and accessories - Inspection and maintenance of LPG cylinder valves at time of periodic inspection of cylinders EN ISO 14245, Gas cylinders - Specifications and testing of LPG cylinder valves - Self-closing (ISO 14245) EN ISO 15995, Gas cylinders - Specifications and testing of LPG cylinder valves - Manually operated (ISO 15995) kSIST FprEN 1440:2015
FprEN 1440:2015 (E) 7 3 Terms and definitions For the purposes of this document, the following terms and definitions apply. 3.1 competent authority authority or authorities or any other body or bodies designated as such in each State and in each specific case in accordance with domestic law 3.2 competent person person which by combination of appropriate qualification, training, experience, and resources, is able to make objective judgments on the subject 3.3 inspection body independent inspection and testing body approved by the competent authority 3.4 Liquefied Petroleum Gas LPG low pressure liquefied gas composed of one or more light hydrocarbons which are assigned to UN 1011, UN 1075, UN 1965, UN 1969 or UN 1978 only and which consists mainly of propane, propene, butane, butane isomers, butene with traces of other hydrocarbon gases 3.5 periodic inspection activities carried out at defined intervals, such as examining, measuring, testing or gauging the characteristics of a pressure vessel and comparing these with specified requirements 3.6 tare mass sum of the mass of the empty cylinder, the mass of the valve including a dip tube where fitted, and the mass of all other parts that are permanently attached to the cylinder when it is being filled, e.g. fixed valve guard 4 Requirements for periodic inspection The interval between periodic inspections shall be dependent on the content of a written scheme. NOTE 1 A written scheme describes work procedures, criteria, responsibilities and other minimum requirements. The maximum interval between periodic inspections for LPG cylinders shall be 10 years; however it can be extended to 15 years under the following conditions: — for LPG cylinders manufactured before the date 2015-01-01, provided the conditions of Annex B are fully met and approval from the relevant competent authority(ies) has been given; and — for RID/ADR welded steel LPG cylinders, provided the requirements of Annex D are fulfilled and approval from the competent authority has been given. Periodic inspections/tests shall be carried out by a competent person under the authorization of an inspection body based on a written scheme and in accordance with the requirements specified in Table 1. kSIST FprEN 1440:2015
FprEN 1440:2015 (E) 8 NOTE 2 RID [1] and ADR [2] include detailed requirements on the qualification, obligations, accreditation and approval of these inspection bodies. Cylinders rejected shall be segregated and shall be either reconditioned, re-tested or rendered unserviceable. The decision to render a cylinder unserviceable can be taken at any stage during the periodic inspection procedure. With agreement by the owner, a cylinder shall be rendered unserviceable in accordance with EN 12816 such that it cannot be re-issued into service as a pressure vessel. NOTE 3 In some countries render unserviceable means scrapping. NOTE 4 With the agreement of the competent authority, the proof pressure test of cylinders can be replaced by an equivalent method based on acoustic emission testing, ultrasonic examination or a combination of acoustic emission testing and ultrasonic examination. EN ISO 16148 [4] can be used as a guide for acoustic emission testing procedures. NOTE 5 Tests can be performed in any order as determined by the written scheme. kSIST FprEN 1440:2015
FprEN 1440:2015 (E) 9 Table 1 — Requirements for periodic inspection Cylinder types Maximum periodic inspection interval Tests Brazed steel cylinders in conformance with EN 12807 or equivalent standard. 10 years — External visual inspection as described in 5.1. and Annex A; — Proof pressure test (hydraulic proof pressure test or, with the agreement of the competent authority, a pneumatic proof test followed by a leak test) as described in 5.2; — Internal condition check as described in 5.3 and Annex A; — Inspection of threads as described in 5.4; — Inspection of valves as described in 5.5. Welded steel cylinders in conformance with EN 1442, EN 13322–1 or equivalent standard (e.g. national codes). — 10 years; or — 15 years under the conditions of Annex B (cylinders manufactured before 1st January 2015); or — 15 years under the conditions of Annex D. Welded steel cylinders with a water capacity of less than 6.5 l. 10 years As for welded steel cylinders in conformance with EN 1442 (see above), or with the agreement of the competent authority, as specified in Annex E. Non RID/ADR welded and brazed steel cylinders. As determined by the competent authority. As specified in Annex C. 5 Inspections and tests 5.1 General Relevant cylinder data shall be identified before any inspections or tests are carried out. Cylinders which cannot be safely emptied of gas shall be set aside for special handling. Cylinders with inoperative or blocked valves shall be set aside for safe valve removal. Before preparing for inspection, manufacturer's guidelines shall be taken into account to avoid any damage to the cylinders. Any chemical solutions and/or cleaning methods used shall be selected to ensure that they do not adversely affect cylinder material. 5.2 External visual inspection 5.2.1 Preparation for external visual inspection a) If necessary, the cylinder shall be cleaned and have all loose coatings or labels, corrosion products, tar, oil or other foreign matter removed from its external surface, b) Care shall be taken to avoid damaging the cylinder, c) When cylinders are treated by a process that might remove cylinder material, the inspection body shall decide whether a thickness test is required, e.g. ultrasonic thickness check. kSIST FprEN 1440:2015
FprEN 1440:2015 (E) 10 NOTE Cleaning methods include wire brushing, shot blasting (in accordance with EN ISO 8504 [6] series and EN ISO 8501-1 [5]), water jet cleaning, chemical cleaning or other suitable methods, that do not adversely affect any part of the cylinders. 5.2.2 Inspection procedure LPG cylinders shall be inspected for: a) dents, cuts, gouges, bulges, cracks, laminations or punctures while applying the criteria for rejection in Annex A; b) corrosion, applying the criteria for rejection given in Annex A; while giving special attention to areas where water can be trapped EXAMPLE at the base of the cylinder; the junction between the cylindrical shell and the foot-ring; the junction between the cylindrical shell and the valve guard or shroud; and hidden corrosion (e.g. under handles). c) other defects (e.g. depressed bung or fire damage) while applying the criteria for rejection given in Annex A; d) integrity of all permanent attachments; and e) integrity of all mandatory permanent markings. 5.2.3 Rejection criteria The specific requirements for external visual inspection of LPG cylinders are described in Annex A including defect descriptions and rejection limits. 5.3 Proof pressure test 5.3.1 General The test shall consist of one of the proof pressure tests described in 5.3.2 and 5.3.3. Proof pressure testing, according to 5.3.3, requires the agreement of a competent authority. The pneumatic proof test as described in 5.3.3 shall only be implemented where such an operation does not entail any danger. Pressure gauges that are used to read the cylinder test pressure, shall be in accordance with EN 837-1:1996 and EN 837-3:1996, accuracy class 1,6 or better. They shall be calibrated or checked for accuracy against a master gauge at regular intervals and not less frequently than once every six months. The master gauge shall be re-calibrated in accordance with national requirements. All joints within the system shall be leak tight. The test equipment shall not restrict the expansion of the cylinder. 5.3.2 Hydraulic proof pressure test 5.3.2.1 General A non-corrosive liquid that is compatible with the material of construction of the cylinder shall be used as the test medium. kSIST FprEN 1440:2015
FprEN 1440:2015 (E) 11 5.3.2.2 Preparation of cylinders a) Cylinders shall be depressurized in a safe and controlled manner before proceeding. b) The external surface of the cylinder shall be in such a condition that any leak can be detected. If the cleaning method involves the wetting of the outside surface or if the outside surface is wet due to outdoor storage conditions, the outside surface shall be completely dried before commencing the test procedure. 5.3.2.3 Test equipment The design and installation of the equipment and the cylinders connected to it shall ensure that no air is trapped in the system. A device shall be fitted to the test equipment to ensure that no cylinder is subjected to pressure in excess of its test pressure by more than the tolerance given in 5.3.2.4. 5.3.2.4 Test procedure a) The cylinder shall be positioned so that the welds are visible during the test. b) The test pressure for a RID/ADR cylinder shall be at least the test pressure marked on the cylinder. For non-RID/ADR cylinders see Annex C. c) The pressure shall be gradually increased in the cylinder until the test pressure is reached. d) The test pressure shall not be exceeded by more than 20 % or 6 bar, whichever is the least. More than one cylinder can be tested at a time provided they all have a test pressure within the tolerance specified. If the cylinder is tested at a higher pressure than that marked, the owner of the cylinder shall calculate the maximum pressure not to be exceeded to ensure that the general membrane stress in the cylinder wall does not exceed 90 % of the guaranteed minimum yield strength of the material used in the finished cylinder. NOTE This can be demonstrated by the following formula: ()−≤×0,920hoPDeRe (1) where Ph
actual test pressure applied to the cylinder by the manufacturer, in bar. D
outside diameter of the cylinder, in millimetres e actual thickness of the material in the finished cylinder (at the point under consideration), in millimetres R0
minimum value of yield strength guaranteed by the cylinder manufacturer for the finished cylinder, in newton's per square millimetre e) Test pressure shall be held for the time necessary to inspect the cylinder and check it out for any leak and/or other defects, but not less than 15 s. f) If there is leakage in the pressure system, it shall be corrected and the cylinders re-tested. g) Cylinders, that do not leak or show any visible permanent distortion after the pressure has been released, shall be deemed to have passed this test. Cylinders showing visible defects shall be examined by a competent person. kSIST FprEN 1440:2015
FprEN 1440:2015 (E) 12 h) Cylinders that fail this test shall be rejected. i) Records of rejected cylinders shall be maintained. 5.3.3 Pneumatic proof test and leak test 5.3.3.1 Preparation of cylinders a) If cylinders have to be depressurized, it shall be carried out in a safe and controlled manner before proceeding. b) Repainting before the pneumatic test shall be limited to a primer coat. The finishing coat shall be applied after the test in order not to mask potential leaks. NOTE The valve can be fitted before the proof test or leak test, see 6.2. 5.3.3.2 Procedure 5.3.3.2.1 Proof test a) Cylinders shall be tested in a safe enclosure to protect against rupture under pneumatic pressure. Adequate safety procedures and measures (e.g. hearing protection) shall be adopted to protect personnel in charge of the test. b) The test pressure for a RID/ADR cylinder shall be at least the test pressure marked on the cylinder. For non-RID/ADR cylinders see Annex C. c) Where a separate pressure relief valve is fitted, an adequate margin of safety shall be maintained between the pneumatic proof test pressure and the pressure setting of the pressure relief valve. Where necessary, the pressure relief valve shall be removed and the port plugged for testing. d) After the cylinder has been placed in a safe enclosure, it shall be charged with the pneumatic test medium (e.g. air, nitrogen) to the test pressure and held at that pressure for at least 5 s. The gas to be used for testing shall be non-flammable to avoid any risk of internal explosion. The cylinder shall pass the proof test if it does not burst. The cylinder shall then be isolated from the pressure source. NOTE Care needs to be taken to avoid corrosion if full water immersion is used. 5.3.3.2.2 Leak test a) The pressure shall be reduced to not less than 6 bar. The pressure drop shall be monitored in a safe and controlled manner. b) The reduced pressure shall be held for the time necessary to inspect the cylinder and to check for any leaks. c) Cylinders that do not leak or show any visible permanent distortion after the pressure has been released shall be deemed to have passed this test. NOTE Care needs to be taken to avoid corrosion if full water immersion is used. d) Cylinders that fail shall be rejected. e) Records of rejected cylinders shall be maintained. kSIST FprEN 1440:2015
FprEN 1440:2015 (E) 13 5.4 Check of the internal condition of the cylinder 5.4.1 Check of the internal condition of welded steel cylinders 5.4.1.1 General The check shall consist of one of the two tests, as described in 5.4.1.2 and 5.4.1.3. 5.4.1.2 Internal visual inspection 5.4.1.2.1 Preparation of cylinders a) Cylinders shall be depressurized in a safe and controlled manner before proceeding. b) Valves shall be removed from cylinders. c) Where necessary, residual liquid and possible foreign matter shall be removed from the inside of the cylinder. 5.4.1.2.2 Procedure a) Cylinders shall be inspected internally fo
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