1. 3.2.5 Student Book © 2004 Propane Education & Research CouncilPage 1 3.2.5 Identifying Procedures for Requalifying DOT Cylinders by CGA External Visual Inspection Method DOT regulations require that cylinders used to transport hazardous materials in commerce must be DOT specification containers approved for the commodity to be shipped, & periodically requalified according to DOT regulations. In this module you will learn to identify: (1)DOT requirements for inspecting & requalifying cylinders in LP-gas service (2) Procedures for visually inspecting & requalifying DOT cylinders in LP-gas service

2. 3.2.5 Student Book © 2004 Propane Education & Research CouncilPage 1 DOT Requirements for Inspecting & Requalifying Cylinders Specification DOT/ICC 4B, 4BA, 4BW and 4E cylinders used in LP-gas service must be requalified: within 12 years after date of manufacture, and every 12 years thereafter if requalified by water-jacket pressure test, every 7 years thereafter if the proof pressure test requalification method is used, or every 5 years thereafter if requalified by external visual inspection conforming to CGA standards in CGA Pamphlets C-6 or C-6.3

3. 3.2.5 Student Book © 2004 Propane Education & Research CouncilPage 1 DOT Definitions CondemnA determination that a cylinder is unserviceable for the continued transportation of hazardous materials in commerce and the cylinder may not be restored by repair, rebuilding, requalification, or any other procedure. DefectAn imperfection requiring removal of the cylinder from service. RebuildThe replacement of a pressure part (e.g. a wall head or pressure fitting) by welding.

4. 3.2.5 Student Book © 2004 Propane Education & Research CouncilPage 2 DOT Definitions RejectedA cylinder that cannot be used for the transportation of a hazardous material in commerce without repair, rebuilding, and requalification. RepairA procedure for correction of a rejected cylinder that may involve welding. RequalificationThe completion of a visual inspection and/or the test(s) required to be performed on a cylinder to determine its suitability for continued service.

5. 3.2.5 Student Book © 2004 Propane Education & Research CouncilPage 3 DOT Definitions RIN(Requalification Identification Number) a code to uniquely identify a cylinder requalification, repair, or rebuilding facility. Visual Inspection An internal or external visual examination, or both, performed as part of the cylinder requalification process.

6. 3.2.5 Student Book © 2004 Propane Education & Research CouncilPage 3 DOT Required Requalification Records 49 CFR § 180.215 sets out DOT requirements for cylinder requalification reports and record retention. Facility Records 1.Current copies of DOT regulations applicable to cylinder requalification done at the facility 2.A copy of Compressed Gas Association (CGA) or American Society for Testing and Materials (ASTM) standards applicable to cylinder requalification done at the facility 3.Current requalifier identification number (RIN) issuance letter (if applicable)

7. 3.2.5 Student Book © 2004 Propane Education & Research CouncilPage 3 DOT Required Requalification Records Facility Records 1.the expiration of the requalification period (5 years for external visual inspections), or 2.until the cylinder is again requalified, whichever occurs first. The person who performs the requalification must maintain daily records of visual inspections and pressure tests until either:

8. 3.2.5 Student Book © 2004 Propane Education & Research CouncilPage 4 DOT Required Requalification Records Facility Records Requalification record pages for external visual inspections must document the following: Cylinder serial number Marked (service) pressure Manufacturer’s name or symbol, if present Disposition Date of requalification DOT specification number Actual dimensions Result of visual inspection Rejection or Condemnation

9. 3.2.5 Student Book © 2004 Propane Education & Research CouncilPage 4 Requalification Markings V10001 0604 E V10001 V10001 0604 E Valid for 5 years from the date Valid for 5, 7 or 12 years from the date, depending on the meaning of “ x ” Valid for 5 years from the date

10. 3.2.5 Student Book © 2004 Propane Education & Research CouncilPage 5 Requalification Methods Water-Jacket Pressure Test – DOT cylinders being tested by the manufacturer or requalified by a water-jacket pressure test are pressurized to two times the design working pressure of the cylinder. During the test, a metal jacket filled with water surrounds the cylinder. This water jacket is used to measure the amount of permanent expansion of the cylinder body when it is under pressure. Month & year marked only (12 years) Proof Pressure Test -- “S” requalification mark (7-years)

11. 3.2.5 Student Book © 2004 Propane Education & Research CouncilPage 6 Requalification Methods External Visual Inspection – The inspection must conform to Compressed Gases Association (CGA) standards. “E” requalification mark (5-years) Step 1:Determine the required requalification date for the DOT cylinder.

12. 3.2.5 Student Book © 2004 Propane Education & Research CouncilPage 7 External Visual Inspection Procedures Figure 2. Requalification Periods for DOT Cylinders

13. 3.2.5 Student Book © 2004 Propane Education & Research CouncilPages 6 - 9 External Visual Inspection Procedures Step 2:Obtain and complete a visual inspection report form. OK Indicates the cylinder has passed. RMIndicates the cylinder has failed a particular step(s) of the procedure. The cylinder must be repaired and requalified by an approved repair station before being returned to service. SCIndicates the cylinder has failed a particular step(s) and must be scrapped or condemned. One of the following marks should be used for “Disposition”:

14. 3.2.5 Student Book © 2004 Propane Education & Research CouncilPages 6 - 10 External Visual Inspection Procedures Step 3:Prepare the cylinder for inspection. Step 4:Inspect the cylinder for fire exposure. Aluminum cylinders (4E) that are exposed to fire must be removed from service immediately, condemned, and scrapped. Steel cylinder must be either condemned or rejected depending on condition. (See Rejection Criteria)

15. 3.2.5 Student Book © 2004 Propane Education & Research CouncilPages 11 & 12 External Visual Inspection Procedures Step 5:Inspect the cylinder for general distortion. Figure 3. General Distortion: Bulge in Shoulder of Cylinder

16. 3.2.5 Student Book © 2004 Propane Education & Research CouncilPages 11 & 12 External Visual Inspection Procedures Figure 4a. Measuring for Bulge or Distortion

17. 3.2.5 Student Book © 2004 Propane Education & Research CouncilPages 11 & 12 External Visual Inspection Procedures Step 5:Inspect the cylinder for general distortion. (See Rejection Criteria) Figure 4b. Measuring for Bulge or Distortion

18. 3.2.5 Student Book © 2004 Propane Education & Research CouncilPage 13 External Visual Inspection Procedures Step 6:Inspect the cylinder neck or valve opening for damage. (See Rejection Criteria) Figure 5. Damaged Neck: Leaning Cylinder Valve

19. 3.2.5 Student Book © 2004 Propane Education & Research CouncilPages 14 - 16 External Visual Inspection Procedures Step 7:Check all cylinder attachments for general damage. (See Rejection Criteria) Figure 6. Neck Ring Damage on Motor Fuel Cylinder

20. 3.2.5 Student Book © 2004 Propane Education & Research CouncilPages 16 - 18 External Visual Inspection Procedures Step 8:Weigh the cylinder—Multiply the tare weight by.95 to determine the minimum tare weight allowed for the cylinder. (See Condemnation Criteria) Step 9:Inspect the cylinder for dents. (See Rejection Criteria)

21. 3.2.5 Student Book © 2004 Propane Education & Research CouncilPages 19 & 20 External Visual Inspection Procedures Step 10:Inspect the cylinder for cuts, digs, and gouges. (See Condemnation Criteria)

22. 3.2.5 Student Book © 2004 Propane Education & Research CouncilPages 21 - 23 External Visual Inspection Procedures Step 11:Inspect the cylinder for corrosion. (See Condemnation Criteria) Figure 9. Pit Gauge Measuring Crevice Corrosion

23. 3.2.5 Student Book © 2004 Propane Education & Research CouncilPages 21 - 23 External Visual Inspection Procedures Step 12:Check the cylinder under pressure. If the cylinder valve threads indicate a leak, the cylinder valve should be retightened and checked for leakage again. If the cylinder valve threads continue to leak, the cylinder should be rejected (RM). The cylinder should also be rejected if any other area indicates leakage.

24. 3.2.5 Student Book © 2004 Propane Education & Research CouncilPages 25 & 26 External Visual Inspection Procedures Step 13:Properly process the cylinder according to the results of the inspection. If a condemned cylinder belongs to a customer or someone other than the company, the cylinder owner must be notified in writing that the cylinder is condemned and may not be filled with hazardous material and offered for transportation in commerce. With the approval of the cylinder’s owner, stamp a series of X’s over the DOT specification number and pressure stamping, or stamp “CONDEMNED” on the shoulder, top head, or neck using a steel stamp.

25. 3.2.5 Student Book © 2004 Propane Education & Research CouncilPages 27 - 30 Time to See If You Got the Key Points of This Module… Complete the Review on pages 27 & 28. See if you are ready for the Certification Exam by checking off the performance criteria on page 29.