Compressed Gas Association CGA C-6.1—2019 SAU aU Ae INSPECTION OF HIGH PRESSURE ALUMINUM ALLOY COMPRESSED GAS CYLINDERS SEVENTH EDITIONPace i : COMPRESSED GAS ASSOCIATION, INC. CGAC-6.1—2019 PLEASE NOTI The information contained in this document was obtained from sources believed to be reliable and is based on technical information and experience currently available from members of the Compressed Gas Association, Inc. and others. However, the Association or its members, jointly or severally, make no guarantee of the results and ‘assume no liabilty or responsibility in connection with the information or suggestions herein contained. Moreover, it should not be assumed that every acceptable commodity grade, test or safety procedure or method, precaution, ‘equipment or device is contained within, or that abnormal or unusual circumstances may not warrant or suggest further requirements or additional procedure ‘This document is subject to periodic review, and users are cautioned to obtain the latest edition. The Association invites comments and suggestions for consideration. In connection with such review, any such comments or ‘suggestions will be fully reviewed by the Association after giving the party, upon request, a reasonable oppor- tunity to be heard. Proposed changes may be submitted via the Internet at our website, www caznel com This document should not be confused with federal, state, provincial, or municipal specifications or regulations: insurance requirements; or national safety codes, While the Association recommends reference to or use of this document by government agencies and others, this document is purely voluntary and not binding unless adopted by reference in regulations, Aisting of all publications, audiovisual programs, safety and technical bulletins, and safety posters is available via the Intemet at our website at www caanet com. For more information contact CGA at Phone: 703-788-2700, ext. 799. E-mail: customerservice@cganet com, Work tem 18-008 linder Specification NOTE—Technical changes from the previous edition are undertined. NOTE—Appendices A, B, and C (Informative) are for information only. SEVENTH EDITION: 2019 ‘SIXTH EDITION: 2013 (corrected 4/14/2015) FIFTH EDITION: 2008 FOURTH EDITION: 2002 (© 2019 The Compressed Gas Association, Inc.All igh reserved, {ll materials contained in this work are protected by United States and intemational copyright laws. No part of this work may be eproduced or transmitted in any form or by any means, electronic or mechanical including photocopying, recording. ar any information storage and retrieval system without permission in wriing fom The Compressed Gas Association, Ine. All requests for Bermsion to reproduce material from this work shouldbe directed to The Compressed Gas Associaton, Inc. 8484 Westpark Drive, Suite 220, McLean, VA 22102. You may not aller or remove any trademark, copyright or other notice from this workCGAC-6.1—2019, COMPRESSED Gas ASSOCIATION, INC. Pace il Contents 1 Introduction, ‘Scope Definitions. Preparation for inspection 4.1” Inspection equipment 42 Valve removal and venting 4.3 Aluminum alloy cylinder identification 44° Cleaning 5 _ Inspection criteria 5.1 Ultrasonic examination visual inspections 52 Markings... 5.3 Corrosion limits. 5.4 — Cuts, digs, and gouges. 5.5 Wall loss 56 Dents 57 Leaks and holes 58 Bulges. 5.9 Fire and thermal damage 5.10 Neck defects, 5.11 Threads and valving 512 Bow. 8 Condemning a cylinder. 7 References. 8 Additional references, Figures. Figure 1—Exemption marked cylinder Figure 2—3AL marked exemption cylinder Figure 3—Cylinder with pitting corrosion Figure 4—Gouged cylinder Figure 5—Dented cylinder Figure 6—Foid Figure 7—Cylinder characteristics Figure 8—Valley. Figure 9—Light and mirror used to inspect threads and crown Figure 10a—Neck crack Figure 10b—Neck crack Figure 11—Too! stop mark Appendices ‘Appendix A—Eddy current devices (Informative) Appendix B—Sustained load cracking (SLC) (Informative) ‘Appendix C—Heat exposure and condemning aluminum alloy cylinders (Informative). Page Nomaasann 7 18 20CGAC-6.1—2019, ComPRESSED GAs ASSOCIATION, INC, Pace 1 1 Introduction Uniess otherwise provided for by special permit, equivalency certificate (formeriy called permit of equivalent level of safety), or regulations, U.S, Department of Transportation (DOT) and Transport Canada (TC) require that cylinders used for the transportation of compressed gases are requalified periodically by visual inspection fol lowed by hyarostatic testing if they are to remain in service (see CGA C-1, Methods for Pressure Testing Com- pressed Gas Cylinders) [1] However, a cylinder that was charged or filed before the requaliicaion becomes due may remain in service unt it has been emptied. U.S. regulations in Part 180 Subpart C of Title 49 of the Code of Federal Regulations (49 CFR) and equivalent Canadian regulations in Clause 24 of Canadian Standards ‘Association (CSA) 8339, Cylinders, spheres, and tubes for the transportation of dangerous goods, identify the inspection and hydrostatic testing requirements for most cylinders (2, 3]. Cylinders fabricated in accordance with DOT, TC, or the former Canadian Transport Commission (CTC) permits, equivalency certficate/permit of equiv- alent level of safety, or exemptions/special permits shall be requalfied as specified in the exemption/special permit, equivalency certficate/permit, or CTC permit. These documents can be obtained from DOT, TC, or the ‘manufacturer. The approval of the 3AL specification in 49 CFR 178.46 (July 2, 1982) consolidated the majority of the exemptions and special permits for aluminum alloy cylinders into one manufacturing regulation [2]. Canadian specification TC-3ALM also consolidates specification CTC-3AL and permits for aluminum alloy cylinders into regulations [3 4 Both DOT and TC have provisions in their regulations for introduction of new cylinder designs, materials, and ‘fabrication techniques. Before implementation of CTC/DOT specification 3AL and TC specification 3ALM, alumi- num alloy cylinders were manufactured under special permits and/or exemptions E 6498, E 7042, E 8107, E 8364, E 6422, CTC SP 890, or CTC SP 922. Permit or exemption numbers are stamped on the shoulder of the cylinder. These cylinders may be continued in use in Canada. In the United States, these cylinders (with the exception of CTC SP 922) may be continued in use but shall be remarked in compliance with 49 CFR 173.23 at the time of the first retest following July 2, 1962 [2]. Such remarking is not authorized for all permitted cylinders, In the United States, DOT exemptions E 6498, E 7042, E 8107, E 8364, and E 8422 were previously issued, ‘hich identified the manufacturing, usage, and inspection requirements of these cylinders. These exemptions have been superseded by DOT specification 3AL and copies of the exemptions are no longer required. Cylinders marked with “S.P.” preceding the previously noted exemption numbers, designating special permits, are also covered by DOT specification 3AL. Some cylinders with the previously noted markings may be preceded by *CTC* indicating compliance with the CTC requirements, for example, CTC/DOT E 6498-1800. Exemption and ‘special permit cylinders shall be remarked at the time of the first hydrostatic testing occurring after July 2, 1982 Requirements for remarking can be found in 49 CFR 173.23(c), which states that after July 2, 1982, a seamless ‘aluminum alloy cylinder manufactured in conformance with and for use under DOT exemption E 6498, E 7042, 8107, E 8364, or E 8422 may be continued in use if marked before or at the time of the next retest with the specification identification 3AL immediately above the exemption number, or if the DOT mark (i.e, DOT-3AL 1800) is added in proximity to the exemption marking [2]. See Figures 1 and 2 for examples of exemption marked cylinders. Experience in the inspection of cylinders is an important factor in determining the acceptability of a given cylinder for continued service. Inspectors evaluating cylinders shall consult the manufacturer or other knowledgeable sources, Existing regulatory markings shall remain intact. * References are shown by bracketed numbers and are listed in order of appearance in the reference sectionCGAC-6.1—2019, COMPRESSED GAS ASSOCIATION, INC. Pace 3 + CGAC-62, Standard for Visual Inspection and Requalification of Fiber Reinforced High Pressure Cylinders (3 + CGAC-63 17]; = CGAC-20 (6); © CGAV-11, Guideline for the Installation of Valves into High Pressure Aluminum Alloy Cylinders 10}; © CGAP-38, Guideline for Devalving Cylinders [11]; and + CGAS-1.1, Pressure Relief Device Standards—Part 1—Cylinders for Compressed Gases [12] 3 Defi ions For the purpose of this standard, the following definitions apply, 3.4 Publication terminology 3.4.4 Shall In the criterion for conformance to specific recom. 344 Is used ont future, ree of requirer 3.1.5 Can Indicates a possibilty or ablity 32 +hnical definitions 3.21 Bow Cylinder manufactured with a curve in it ike a banana shape. 3.22 Bulge Visible swelling of the container 3.23 Condemned No longer fi for service. A condemned cylinder is required to be removed from service. 3.24 Corrosion Loss of metal thickness by some corrosive media NOTE—Corrosion of aluminum appears as a roughened and discolored area with a white deposit sometimes associated with the corrosion. There are several kinds of 3244 General corrosion Corrosion that covers considerable surface areas of the cylinder, 3.24.2 Line corrosion ‘Series of pits closely spaced as to appear to be in a line. NOTE—This condition is considered more serious than isolated piting,CGA C-6.1—2019, COMPRESSED GAS ASSOCIATION, INC. Pace 5 327 Dent Deformations of the cylinder caused by a blunt object so that the metal is relocated and the wall thickness is not. reduced, see Figure 5. Figure 5—Dented cylinder 328 Fold ‘Sharp visual groove along the length of the cylinder usually in the crown area, see Figure 6. Fold is shown from here Fold Figure 6—Fold 3.2.9 High pressure 11800 psi (12 410 kPa) or greater. 3.2.10 High pressure aluminum alloy cylinders Aluminum alloy cylinders manufactured in accordance with DOT-3AL, CTC-3AL, and TC-3ALM specifications, see Figure 7.CGAC-6.1—2019, COMPRESSED GAS ASSOCIATION, INC. Pact 7 4 Preparation for inspection 4.4. Inspection equipment 441 Depth gauges, scales, and straightedges Exterior corrosion, denting, bulging, gouges, or digs are normally measured by simple direct measurement with straightedges and depth gauges or scales. In brief, a rigid straightedge of sufficient length is placed over the defect and a scale is used to measure the distance from the bottom of the straightedge to the bottom of the defect. Commercial depth gauges are also available that are especially suitable for measuring the depth of small Cuts or pits. Its important when measuring such defects to use a scale that spans the entire affected area. When ‘measuring cuts, the upset metal shall be removed or compensated for so that only actual depth of metal removed from the cylinder wall is measured 41.2 Inspection light ‘One of the most useful tools for the internal inspection of cylinders is a high intensity light probe, see Figure 9. 4.1.3 Inspection mirror ‘A112 in (13 mm) diameter 2X dental mirror shall be used to aid a visual inspection of internal neck and crown surfaces, see Figure 9. The use of greater magnification can lead to erroneous inspection results, r= j pit source Kf AL Figure 8—Light and mirror used to inspect threads and crown 41.4 Penetrant inspection Dye penetrant materials are available that show surface faults not readily visible o the unaided eye. Excessive or heavy use of penetrant can obscure the feature being sought 41.5 Other devices Other inspection methods such as eddy current are available and can be used to help detect features, see Ap- Pendix A, ‘The use of eddy current helps find neck cracks hard to detect by visual evaluation. After the device does detect, something, it shall be confirmed by a 2X dental mirror. Eddy current is required for the neck inspection of cylin- ders manufactured from aluminum alloy 6351 to help detect sustained load cracking (SLC), see Appendix B.CGAC-6.1—2019, JOMPRESSED GAS ASSOCIATION, INC Pace 9 5 Inspection criteria 5.1 Ultrasonic examination visual inspections When performing UE for the purposes of cylinder requalification, an external visual inspection of the aluminum alloy cylinder is necessary. The external visual inspection shall be completed in accordance with this standard and shall include the following regions of the cylinder: ‘+ shoulder and neck region; © sidewall; and ‘© base bottom. See Figure 7 and §.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, and 5.10 Ia cylinder’s valve is removed, the examiner shall inspect the following internal regions: ‘+ shoulder and neck; = neck threads; sidewall; and + base bottom, See 5.3, 5.4, 5.5, 56, 5.7, 5.8,5.9, and5.10, Itis not necessary to remove a cylinders valve to perform UE unless: * an augmented inspection such as eddy current testing is required to be performed of the cylinder neck threads; or ‘© required by regulations, 5.2 Markings Specification-required cylinder markings shall be legible and complete. Markings required by specifications for cylinder manufacturers shall be permanent and meet regulatory requirements. 5.2.1 Prohibited markings The plus (+) stamp mark is not allowed on aluminum alloy cylinders. The plus (+) mark signifies the qualification of a steel cylinder for filing to a settled pressure 10% greater than the stamped service pressure. With aluminum alloy cylinders, the full settied pressure shall not be greater than the service pressure limit stamped on the cylin- der. Condemn cylinders that have this plus (+) mark on them, Regulatory markings shall appear in the order required. Additional markings are allowed provided they do not ‘obscure or contradict the required markings. Owner information may be included in the markings as well as other symbols. Condemn all cylinders with prohibited markings (for example, other regulatory marks that do not apply to the cylinder, sidewall markings not approved by a regulatory authority) 5.2.2 Requalification dates The regulations of 48 CFR 160.213 require that the requalification identification number (RIN) be stamped be- tween the month and year of requalification [2]. Canadian Transportation of Dangerous Goods Regulations also require that the requalification facility's registered mark be stamped on the cylinder as prescribed in Clause 24.6.3 of CSA B339 [13, 3].CGAC-6.1—2019, COMPRESSED Gas ASSOCIATION, INC. Pace 11 5.5 Wall loss ‘Most internal or external surface treatment processes have the potential to remove aluminum alloy material from the sidewall of the cylinder. The removal can be in a localized area or overall. Therefore, itis essential that these processes are performed before the final requalification test. The wall thickness shall be determined after the use of any metal removal process, regardless of the quantity of material loss that has occurred. Any cylinder subjected to a treatment or reconditioning process used to clean, alter, or improve the finish of a cylinder after it has entered the market shall have its wall thickness verified by UE or some other means, at different locations ofthe cylinder. ‘Accylinder verified to have a wall thickness less than the limits specified for general corrosion (see 5.3.1) shall be ‘condemned. Processes that can produce loss of wall include: ‘+ cleaning internal or external surfaces (see 4.4) ‘+ cutting, grinding, trimming, or shaving metal from the internal or external surfaces; and ‘= application of chemicals that dissolve or react with aluminum, 5.6 — Dents Dents that do not reduce the wall thickness may be tolerated. Dents up to 1/16 in (1.59 mm) in depth when the major diameter of the dent is 2 in (50.8 mm) or greater are permissible, See Figure 5. Cylinders with one or more dents that are less than 2 in (50.8 mm) in diameter of any depth shall be condemned. Cylinders with dents deeper than these allowances shall be condemned. NOTE—Thereis contusion regarding the previous requirement. Shallow dents of small size have greater stress atthe edge Of the dent than that same shallow dent ofa large diameter. Such higher stress areas can lead to cylinder failure making the smaller diameter dent a safely risk. Cyinders wih small (even shallow) dents shall be condemned 5.7 Leaks and holes 5.7.41 Detection Leaks and holes can be found in a cylinder by different means. A close visual inspection of the exterior and interior surfaces is strongly recommended for any cylinder reported to lose pressure during storage. Use of a dye or penetrant can be helpful, see 4.1.4. A cylinder that is leaking or that has a hole could rupture ifit is pressurized, so checking for leaks with a soap solution or immersion in water while the cylinder is under pressure is not ‘ecommended. Holes can be concealed with construction material and then painted or attempts at plugging holes ccan be seen. If the cylinder owner has identified a time when the cylinder lost pressure for unknown reasons, a leak or hole could be suspected. NOTE—Hydrosiatic testing can identify 8 cylinder witha leak. Do not pressurize a cylinder that is suspected of having a leak or hole outside atest jacket capable of safely containing or relieving the pressure released from a catastrophic failure, 57.2 Limits Cylinders with leaks through the metal shall be condemned. Cylinders found with holes (plugged or not plugged) shall be condemned, Repair of aluminum alloy cylinders with leaks or holes is not allowed 58 Bulges Cylinders are manufactured with a reasonably symmetrical shape. A bulge may be detected by rolling the cylinder on a flat surface to detect any raised area on the surface. Also, a straightedge may be laid across the suspected bulge to highiight this feature. Cylinders with one or more definite visible bulges shall be condemned 5.9 Fire and thermal damage 5.9.1 Fire damage Aluminum alloy cylinders subjected to the action of fre (for example, in a fire) are considered unsafe. For con- demnation criteria, see 5.9.5,CGAC-6.1—2019, CompresseD GAs ASSOCIATION, INC. Pace 13, * when the metal has reached or exceeded 350 °F (177°C); ‘+ when heat sensing coatings or cylinder applied indicators show the cylinder is no longer safe to fll; and ‘+ when showing arc burns (arc strikes). All cylinders with the following indications of or suspected or thermal damage shall be given a hardness test (in different areas of the cylinder manufacturer recommendations), a hydrostatic test, or in some other way verified to be of the proper strength by a nondestructive means! ‘+ any one or more indications listed in 5.9.4; * suspected of thermal damage by any process listed in 5.9.2; * reported to have been stored andlor used near a heat source (for example, furnace, oven, etc); and + heated to an elevated unknown temperature In some cases, the inspector may not have direct knowledge of one or more of the previous situations. The inspector may have been made aware by the cylinder owner, user, indications, or third-hand information NOTE—Oylinders known to have been subjected to the action of @ fre, having been heated at or over 350 °F (177 °C), or having signs of an arc burn (are strike) shall be condemned and shall nat be strength tested. These are required condemning features per regulations. 5.10 Neck defects Cylinder necks shall be examined for cracks, folds, and other flaws, 5.10.1 Neck cracks Unless otherwise specified by regulatory requirements, all aluminum alloy cylinders shall be internally Inspected for cracks in the neck region. The inspection shall be visual but may be confirmed using an electronic nonde- structive testing (NDT) device, see Appendix A. Some aluminum alloy cylinder manufacturers do not recommend Using such devices except when and where required by regulations. Cylinders made of aluminum alloy 6351 shall be tested for neck cracks using an eddy current device. Instructions for set up, use, and allowable criteria are found in regulations [2, 3) Ifa device is used to detect neck cracks, then any indication ofa feature made by the device chall be visually confirmed, see 4.1.5. Cylinders with confirmed cracks shall be condemned according to regulatory requirements. Repair of neck cracks Is not allowed, see Figures 10a and 10 Figure 10a—Neck crackCGAC-6.1—2019, COMPRESSED GAS ASSOCIATION, INC Page 15 5.10.2 Folds Folds found in the crown region that extend into the base of the neck can appear to be a crack, found by the internal visual inspection of the neck. Condemn all cylinders with folds that exceed two continuous full threads, see Figure 6 5.10.3 Valleys Cylinders with one or more valleys are acceptable for use provided the valley(s) does not enter into the minimum ‘number of required threads, see 5.11 and Figure 8 5.11 Threads and valving Cylinder neck threads shall be 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. Cylinders shall be rejected if the required numbers of effective (engaged) threads are materially reduced so that a gas-tight seal Cannot be obtained by reasonable valving methods. Unacceptable thread defects include threads that are galled, worn, corroded, broken, cracked, nicked, and “double threaded’ from forcing an incorrect valve into the threads, Condemn all cylinders with unacceptable thread defects 5.11.1 O-ring gland Many aluminum alloy cylinders have an O-ring gland and straight threads. Both the O-ring and lubricant, if used, shall be compatible withthe lading. Where the cylinder is part of a certified assembly such as in the self-contained breathing apparatus (SCBA) unit used by firefighters and emergency responders, the only O-ring used shall be the O-ring type originally certified with the assembly. In the case of cylinders used in SCBA service, any replace- ‘ment O-ring shall be obtained from the SCBA unit manufacturer. O-rings shall be clean and smooth, Replace damaged O-rings. 5.11.2 Valving/devalving ‘When valving, the thread configuration (straight versus tapered, similar inlet specifications) shall be determined. {In some cases, a valve with straight threads can ft into a cylinder with tapered threads and damage to the cylinder or valve could result. A thread gauge may be used to verify the size and type of threads, ‘The installation of valves shall meet the requirement of CGA V-11 [10]. The devalving or valve removal shall meet the requirements ofthe written procedures developed using the guidelines in CGA P-38 [11] 5.11.3 Gas service DOT specifies the use of specific thread types for aluminum alloy cylinders in oxygen service. Refer to 49 CFR 173.302(b)(2) [2]. For equivalent Canadian requirements refer to CSA B340, Selection and use of cylinders, ‘spheres, tubes, and other containers for the transportation of dangerous goods, class 2 (4) 512 Bow Accylinder with a bow is an acceptable condition 6 Condemning a cylinder When visual inspection detects a defect requiring that the cylinder be condemned, the cylinder shall be perma- rently removed from service (see Section 5). In addition, the cylinder shall have a series of Xs stamped through the specification number and marked service pressure or the word CONDEMNED stamped on the shoulder, top head, or neck using a steel stamp as required in regulations. Altemately, the cylinder may be rendered unable to Contain gas under pressure with permission of the cylinder owner. When a cylinder has been condemned, the cylinder owner shall be notfied in writing that the cylinder is condemned and may not be filed nor offered for transportation in commerce (unless otherwise specified by regulatory authority) where use of a specification Packaging is required.CGAC-6.1—2019, Compresse Gas ASSOCIATION, INC. Pace 17 Appendix A—Eddy current devices (Informative) Besides visual inspections (for material loss and defects), there are NDT techniques that are less likely to miss. defects than the human eye, ‘Some of these testing techniques use eddy current. Eddy current devices are especially suitable to detect neck cracks, see 5.10 There are commercially available testing units that easily identify neck cracks and thread defects in cylinders. Contact the cylinder manufacturer for testing recommendations, ‘The use of the eddy current device is required for the detection of neck cracks in aluminum alloy 6351 cylinders at time of requalifcation. For detailed requirements, see 49 CFR 180 Appendix C and CSA B339 Clause 24 [2 aL Ee Isanond evaluation (NDE) technique used for measuring conductivity. coating thickness, ind detection 2 and subsurf ntinuities. This test method lends itself very wel because test results are instantaneous Test 0 ‘also be designed for high-speed inspection in 2 “go/no-go" situation ‘The effectiveness of this technique depends on the electrical conductivity of the material to be tested. Typically, the higher the conductivity of the material the higher the sensitivity of detection. Aluminum all sinless Steels are usually appropriate for this kind of testing. It is sometimes difficult to test ferromagnetic material usin. ‘eddy current Eddy current testing composite materials is always impractical and most often not possible, Applications Before manufacture—Eddy current may be used for the detection of surface and subsurface flaws in the starter rial for fabrication of gas cylinders. Typically, this test pr ‘Suitable for ter stock in the {form of drawn rods, bars, and tubes where. discontinuities such as laminations and surface tears coul the drawan fon. This test method may be used to complement other Ni niques such as ultrasonic testing, itis especiall ive for detecting and quantitying surface breaking discontinuities At time of manufacture—Application of eddy current for inspection of gas cylinders is limited by access to the or tea to be in ‘as well as the surface condition. Rough surface conditions can cause a loss in sensitiv neous interpretation of the signals. Cond measurement can be used in conjunction with hardness {ests for verification of heat treatment response. After manufacture—During service, eddy current may be used to test cylinders for discontinuities includin Cracks. inclusions, and broken threads in the threaded. her locations where discontinuities can de- elop. Testing is li ‘access to the area to be inspected. Eddy current may be used fo measure conductivt to determine exposure to elevated service temperature, which can affect the mechanical properties of aluminum alloy cylindersCGAC-6.1—2019, COMPRESSED Gas ASSOCIATION, INC. Pace 19 Property damage. The 5 year periodic requalification for all-metal 6351 aluminum alloy cylinders provides ample opportunity to discover neck cracks before they lead to leaks, Some cylinder manufacturers, regulatory author- ties, or industries may recommend more frequent visual inspections. For example, the self-contained underwater breathing apparatus (SCUBA) industry recommends an annual visual inspection ofall SCUBA cylinders regard less of make, model, or material. Recommendations are not required to be performed What is most important is that the visual inspection be performed accurately and with diligence. More frequent oor quality inspections will nt discover cylinder imperfections. Diligent properly performed inspections at the ‘current required frequency do find cylinder defects before they can lead to leak(s) or catastrophic failure. As stipulated previously in this standard, any aluminum alloy cylinder with a crack(s) shall be condemned. Like- wise, any cylinder that is leaking shall be condemned. In addition, the inspector and requalification facilty per- sonnel shall be aware that aluminum alloy cylinders made of 6351 alloy shall be tested using an eddy current device, which is required by regulations [2, 3]. Ifthe equipment detects a defect, it shall be confirmed visually.Pace 2, \ESSED GAS ASSOCIATION, CGAC-6.1—2019 Figure 2—3AL marked exemption cylinder 2 Scope This standard has been prepared for the visual inspection of aluminum alloy compressed gas cylinders with service pressures of 1800 psi (12 410 kPa) or greater” This standard does not address all eyinder manufacture defects. Cylinders authorized by regulation may require testing by ultrasonic examination (UE) or pressure test- ing. This standard does not include testing that may be requifed by regulation, UE of aluminum alloy cylinders shall meet the requirements of CGA C-20, Requalification Standard for Metalic, DOT and TC 3-Series Gas Cylinders and Tubes Using Ultrasonic Examination (6). Pressure testing shall meet regulatory requirements. CGA C-6.3, Standard for Visual Inspection of Low Pressure Aluminum Alloy Compressed Gas Cylinders shall be fol lowed for cylinders with lower service pressures [7] ‘Additional publications and standards prepared by the Compressed Gas Association, Inc. (CGA) that can be helpful include: © CGAC-4 II}; + CGA C-6, Standard for Visual Inspection of Steel Compressed Gas Cylinders (8), 2 kPa shall indicate gauge pressure unless otherwise noted as (kPa, abs) for absolute pressure or (kPa, differential) fr difer- ential pressure. AllkKPa values are rounded off per CGA P-11, Gutiline for Metric Practice nthe Compressed Gas Indust) (5)Pace 4, (COMPRESSED GAS ASSOCIATION, INC CGAC-6.1—2019 3.2.4.3 Pitting corrosion Pits can be small and localized or larger and scattered, NOTE—Small isolated pits have very ite effect on the strength ofthe cylinder but the degree of pitting and concentration of the pts determine if the cylinder may continue in service, see Figure 3 Figure 3—Cylinder with pitting corrosion 325 Crack ‘Split or rift in the metal 3.2.6 Cuts, digs, and gouges Detects that are indicated by removed or upset metal NOTE—These defects are associated with oss of wall thickness and are usually caused by a sharp object, see Figure 4 Figure 4—Gouged cylinderCompnesseD Gas, TION, INC, CGAC-6.1—2019 Pace 6 ‘0-809 lane Top eck ‘Crown, shoulder ornead EE TRIO NN ase toot Figure 7—Cylinder characteristics 3.2.41 Minimum design wall thickness Minimum wall thickness as established by the cylinder manufacturer. NOTE—Consult the manufacturer for specific minimum design wall thickness, 3.212 Valley ‘Shallow and smooth elongated depression usually found in the crown area, see Figure 8. on Valieyis'shown trom here “valley Figure 8—ValleyPace 8. COMPRESSED GAS ASSOCIATION, INC, CGAC-6.1—2019 Inspection methods that use magnification over 2X of an area shall not be used fo make a final determination of whether the feature is acceptable or not. Ifthe feature is not readily visible to a 2X dental mirror, then itis not a feature for concem. If the feature does not measure to be outside the allowable criteria, then itis not a feature for concem, 4.2 Valve removal and venting CAUTION: Venting unknown gases from cylinders by improper methods can result in injury or death. If a cylinder is received in the valved condition, care shall be taken to properly and safely vent any contents (if there are any) and safely remove the valve. The inspector shall handle all valved cylinders as ifthe cylinder were pressurized. The inspector shall meet the requirements of the written procedures for valve removal and venting, based upon the guidelines for such procedures provided in CGA P-28 [11] 4.3 Aluminum alloy cylinder identification ‘Aluminum alloy cylinders can be identified by DOT, TC, or CTC markings found on the shoulder of the cylinder. ‘Some of the exemption and special permit numbers of high pressure aluminum alloy cylinders are included in ‘Section 1. Additional information can be obtained from the DOT, TC, or the cylinder manufacturer. 44 Cleaning Judgment is required to determine the extent of cleaning required and whether removal of paint is necessary. At the time of requalification, all mult-layered paint and coatings, foreign materials, temporary labels, or removable sleeves that could interfere with the inspection shall be removed from the external surface so itis prepared for inspection. Remove all attachments that could conceal corrosion or other defects before inspection. If internalex- ternal cleaning is performed in conjunction with periodic hydrostatic retest, cleaning shall be accomplished before hydrostatic or other cylinder testing 441 External cleaning Paint stripping and coating removal shall only be performed with products recommended for aluminum alloys Used under stress. Do not use solutions of strong alkali (caustic), acid, or heat sources such as furnaces or blow torches, Even when a chemical product label indicates it is safe for use on aluminum, it may not be suitable for use on aluminum alloys used under stress or pressure such as aluminum alloy compressed gas cylinders. Some chem- icals are known to or can adversely affect the micro structure of aluminum alloys and change their ability 10 handle pressure. Use only paint and coating removal chemicals approved by the cylinder manufacturer or known to not have such effects on aluminum alloys under stress. Abrasive shot blasting or cleaning methods that remove cylinder material shall not be used. Recommendations from manufacturers or equipment suppliers should be followed. Threads shall be protected during cleaning pro- ‘cesses. Some hard blasting media can imbed itself into and potentially adversely affect the aluminum alloy sur- face. Any blasting media shall be evaluated for possible negative results and not only for its ability to clean the aluminum alloy surface. 4.4.2 Internal cleaning If required, tumble cleaning may be performed with a watery slurry of aluminum oxide pellets, ceramic chips, or other inert media. After tumbling, a thorough flushing is required to remove loose materials and cleaning media, followed by thorough drying. Do not use solutions of strong alkali (caustic) of acid for internal cleaning, see 4.4.1 All processes shall comply with the requirements in 5.5 44.3 Other Other cleaning methods may be used for cleaning (for example, media blasting, vapor honing, etc). Methods, procedures, or chemical cleaning that removes cylinder material shall comply with the requirements in 5.5. Rec- ‘ommendations from cylinder manufacturers should be followed. Threads shall be protected during cleaning pro- cesses. The cleaned cylinder shall be free of all media, by-products, and materials, see 4.4.2Pace 10, COMPRESSED GAS ASSOCIATION. INC CGAC-6 12019 5.3. Corrosion limits The following descriptions of types of corrosion provide requirements for the acceptability for service of aluminum alloy cylinders with these features. The allowable corrosion depths specified are for high pressure cylinders with ‘a wall thickness of 3/16 in (4.76 mm) or greater. 5.3.1 Limits for general corrosion Ifthe wall thickness is unknown, the allowable corrosion depth is 1/32 in (9.79 mm). ifthe wall thickness is known, the maximum allowable corrosion depth is 10% of the minimum design wall thickness. The area of corrosion may be estimated and shall not cover more than an area of 3 in’ (19.4 cn?) regardless of depth of the external and internal combined surface area. Cylinders with general corrosion at the same point on both the internal and external surfaces that when combined have a wall loss of greater than 1/32 in (0.79 mm), show a loss of wall 4greater than 10% minimum design wall thickness, or greater than 3 in* (19.4 cm) in otal are beyond allowable limits. Condemn all cylinders with corrosion beyond these allowable limits. 5.3.2 Limits for Isolated pits Ifthe wall thickness is unknown, the allowable depth of pitting is 1/16 in (1,59 mm). Ifthe wall thickness is known, the allowable depth of pitting is 30% of the minimum design wall thickness. Condemn all cylinders with pitting that exceeds these limits. ‘As an example, for a known wall thickness of 0.345 in (8.763 mm) the allowable pit depth is 0.345 in x .30 = 0.103 in (2.61 mm). The pitting shown in Figure 3 measures 0.086 in (2.18 mm). This is greater than the allowable pit depth for a cylinder with an unknown design wall thickness but is less than the allowable pit depth for a cylinder with a known design wall thickness of 0.346 in (8.763 mm). 5.3.3 Limits for 1e corrosion Ifthe wall thickness is unknown, the allowable ine corrosion depth is 1/32 in (0.78 mm). If the wall thickness is known, the allowable line corrosion depth is 10% of the minimum design wall thickness. The length ofthe line corrosion of allowable depth shall be less than 3 in (76.2 mm). Condemn all cylinders with line corrosion that exceeds these limits 5.4 Cuts, digs, and gouges 5.4.1 Measurement Cuts, digs, and gouges may be measured with suitable depth gauges or with a pipe pit gauge. Any upset metal shall be smoothed to allow true measurements without causing further damage to the cylinder. There are other ‘means to obtain depth estimates of these features such as (for internal pits) picks with a machined notch plate to compare depths. 5.4.2 Limits If the wall thickness is unknown, the allowable cut, dig, or gouge is 1/32 in (0.79 mm) If the wall thickness is known, the allowable cut, dig, or gouge is 10% of the minimum design wall thickness. The length of an allowable cut. dig. or gouge shall be less than 3 in (76.2 mm). Condemn any cylinder with a visually evident cut. dig. or gouge 3 in (76.2 mm) or greater in length regardless of depth and shorter features that are deeper than these allowances ‘As an example, for a gouged cylinder of known design wall thickness of 0.380 in (9.652 mm), the allowable gouge depth is 0.380 in x 10 = 0.038 in (0.96 mm). The gouge in the cylinder in Figure 4 measures 0.06 in (1.52 mm) This is greater than the allowable gouge depth (1/32 in [0.79 mm)) for a cylinder with an unknown design wall thickness, and also greater than the allowable gouge depth (0.038 in [0.965 mm)) for a cylinder with a known design wall thickness of 0.380 in (9.652 mm). The cylinder does not meet these criteria and shall be condemned.Pace 12, COMPRESSED GAS ASSOCIATION, INC. CGAC-6.1—2019 5.9.2 Thermal damage ‘Aluminum alloy cylinders can be permanently damaged by exposure to elevated temperatures. For condemna- tion criteria, see 5.9.5, Processes and conditions that can produce metal temperatures greater than 360 °F (177 °C) include: ‘paint baking, curing, or drying; © oven drying: vacuum baking + vinyl coating: + heat stripping of paint; + application of heat to assist the mixing of gases in cylinders containing gas mixtures; + reactions of contents; and + excessive blasting For condemnation criteria, see 5.9.5. Follow the cylinder manufacturer's recommendations regarding the painting and refurbishing of cylinders. 5.9.3 Arc burns (are strikes) Evidence of arc burs (arc strikes) means a localized area of the aluminum alloy cylinder was heated to a high temperature. Cylinders with arc burns (arc strikes) are considered unsafe and shall be condemned, 5.9.4 __ Inspection for fire and thermal damage Direct and indirect evidence of a cylinder being subjected to the action of fire or evidence of exposure to elevated temperatures includes: ‘+ charting or blistering of the paint or other protective coating; ‘+ metting, cratering, or scarfing of the metal; ‘= adding of welding metal, weld marks, and arc bums (arc strikes); + distorting (for example, bulging) of the cylinder; + metting, scorching, or deformation of the valve handwheel or valve protector; ‘+ charring, blistering, distortion, or discoloration of labels or attachments; * activating a thermal element that is part of a pressure relief device (PRD); and ‘© increases in total or permanent expansion from hydrostatic testing. CAUTION: Do not conceal fire or thermal damage by painting or other means. 5.9.5 Limits Al cylinders in the following category(ies) shall be condemned ‘+ with indications of or suspected thermal damage but not strength tested; ‘+ with indications of or suspected thermal damage that failed to pass the strength test: = when subjected to the action of a fire (for example, in a fire)Pace 14 CompResse Gas ASSOCIATION, INC. CGAC-6.1—2019 Figure 10b—Neck crack A neck with a tool stop mark is to be distinguished from a neck crack. Cylinders with a tool stop mark are ac- ceptable for use, see Figure 11 Aluminum alloy cylinders manufactured from 6351 alloy can exhibit SLC growing over several years of pressuri- zation. Such cylinders should be given diligent and proper inspections at the time of requalification (see Appendix B) and tested using an eddy current device according to regulations [2, 3]. In addition, after using such a device, all indications of features given by the use of the device shall be confirmed by visual inspection before condemn- ing the cylinder. All cyinders with SLC shall be condemned. Aluminum alloy cylinders not made of this alloy are ‘not required to be tested using an eddy current device Figure 11—Tool stop markPace 16, COMPRESSED GAS ASSOCIATION, INC. CGAC-6.1—2019 7 References Unless otherwise stated, the latest edition shall apply. [1] CGA C-1, Methods for Pressure Testing Compressed Gas Cylinders, Compressed Gas Association, Inc. wwwew caanet com [2] Code of Federal Regulations, Title 49 (Transportation) Parts 100-180, U.S. Government Printing Office. ‘wvew ap0,G0v [3] CSA B339, Cylinders, spheres, and tubes for the transportation of dangerous goods, Canadian Standards Association. www csa.ca 4] CSA 8340, Selection and use of cylinders, spheres, tubes, and other containers for the transportation of dangerous goods, class 2, Canadian Standards Association. www csa ca [5] CGA P-11, Guideline for Metric Practice in the Compressed Gas Industry, Compressed Gas Association, Inc. wn eganet com [6] CGA C-20, Requalification Standard for Metallic, DOT and TC 3-Series Gas Cylinders and Tubes using U- trasonic Examination, Compressed Gas Association, Inc. www caanet com I7ICGA C-6, Standard for Visual Inspection of Stee! Compressed Gas Cylinders, Compressed Gas Associa ton, Inc. yeww.cganet.com [8] CGA C-6.2, Standard for Visual Inspection and Requalfication of Fiber Reinforced High Pressure Cylinders, Compressed Gas Association, Inc. you caanel.com [9] CGA C-6.3, Standard for Visual inspection of Low Pressure Aluminum Alloy Compressed Gas Cylinders, Compressed Gas Association, Inc. www caanet com [19] CGA V-11, Guideline for the installation of Valves into High Pressure Aluminum Alloy Cylinders, Com- pressed Gas Association, Inc. ynvw.caanet.com [11] CGA P-38, Guideline for Devalving Cylinders, Compressed Gas Association, Inc. www coanet com [12] CGA S-1.1, Prossure Reliof Device Standards—Part 1—Cylinders for Compressed Gases, Compressed Gas Association, Inc. www caanet.com [13] Transportation of Dangerous Goods Regulations, Transport Canada, Canadian Government Publishing Centre. yw tc-ac.ca 8 Additional references ASNT-1611, Level II Classroom Training Books: Eddy Current Testing, American Society for Nondestructive Testing. wivw.asnt.org CANICGSB-48 14-M86, Advanced Manual for: Eddy Current Test Me nadian | Standards ‘Board, www ipsac-pwasc.gc.ca/ongc-casb/ Hagemaier, Donald J., Fi antals of Eddy Current Testing, The American r Nondestructive Test- ing_ www asnt.org Mester, Michael L_ (tech, ed); Mcintire, Paul (ed.), Nondestructive Testing Handbook-Third Edition, Volume 5: Electromagnetic Testing, The American Society for Nondestructive Testing. ww. asni os McMaster, Robert C. (ed.), Nor live Testing Handbook, First Edition, The American. 3 Nonde- structive Testing. wavw.asnt.oraPAGE 18, COMPRESSED GAS ASSOCIATION, INC. CGAC-6.1—2019 Appendix B—Sustained load cracking (SLC) (Informative) ‘This appendix provides additional information regarding SLC in aluminum alloy cylinders. ‘As the name implies, the SLC process in a cylinder is where cracking occurs in the metal when the cylinder is pressurized (filed). Cracking begins and grows in the head region of a pressurized cylinder. The process requires stress and certain components in the metal alloy but SLC does not always occur. Over the years, all-metal aluminum gas cylinders and some composite cylinders with aluminum liners have been ‘manufactured from different aluminum alloys. Some of these alloys were found to exhibit a characteristic later named SLC. In the United States, the commonly used aluminum alloy that can exhibit SLC is identified by the ‘Aluminum Association alloy number 6351. Its referred to as the 6351 alloy and cylinders manufactured using this alloy are generally referred to as 6351 alloy cylinders or 6351 cylinders. Today, the most commonly used aluminum alloy in North America manufactured to DOT specification 3AL and TC specification TC-3ALM uses the Aluminum Association alloy number 6061. Straight threaded high pressure aluminum alloy cylinders manufactured from 6061 alloy do not develop SLC. B1 Is the aluminum cylinder made from 6351 alloy? CCiff Impact, a division of Parker Hannifin, manufactured cylinders from 6351 alloy before July 1990. Justice Cylinders produced all-aluminum cylinders manufactured from 6351 alloy. They primarily manufactured ‘medical cylinders during the 2 year period from 1984 to 1985, Luxfer USA, now known as Luxfer Gas Cylinders USA, produced 6351 alloy cylinders in the United States to DOT and CTC specifications before June 1988. Cylinders from Luxfer USA with a first hydrostatic test date of 5/88 or earlier are manufactured from 6351 alloy. Some cylinders before 5/88 were manufactured from the 6061 aluminum alloy. ifthe cylinder being tested is dated between December 1987 and June 1988, contact Luxfer Gas Cylinders USA to find out what aluminum alloy was used. ‘The Walter Kidde 6351 alloy cylinder was no longer produced in the United States to DOT and CTC specifications after 1989. Cylinders from Walter Kidde with a first hydrostatic test date of 12/98 or earlier are manufactured from 6351 alloy. Some Walter Kidde cylinders manufactured during 1989 were manufactured from either the 6061 or 16351 alloys. Ifthe cylinder being tested is originally marked in 1989, contact Walter Kidde to find out what alumi- ‘hum alloy was used. Walter Kidde ceased to manufacture high pressure aluminum alloy cylinders in January 1990, ‘Aluminum alloy cylinders manufactured by Catalina Cylinders and Citf Division of Catalina Cylinders have never been manufactured with 6351 alloy. ‘The composite cylinders that were manufactured using 6351 alloy as liners are near or have passed their life limit of 18 years. Because of their age, composite cylinders manufactured using 6351 alloy are no longer eligible for another requalification. B2 Additional information Not all 6351 cylinders will exhibit SLC. Some 6351 cylinders have been in service for 30 years without showing signs of SLC. Some will never exhibit cracking from SLC. In addition, low pressure cylinders are less likely to develop SLC SLC has been closely studied since before 1980. One or more cracks could develop in a cylinder. The conditions needed to crack the metal are thatthe metal is under a sustained load or, inthe case of gas cylinders, the metal is under pressure. A full or nearly ful high pressure 6351 aluminum alloy cylinder could crack slowly in the head ‘and neck region. Evidence and actual experience have shown that SLC takes many years to develop into a large crack or leaking cylinder. If an attempt is made to fil a leaking cylinder, a rupture can occur that could lead to injury, death, orPace 20 COMPRESSED GAs ASSOCIATION, ING. CGAC-6.1—2019 Appendix C—Heat exposure and condemning aluminum alloy cylinders (Informative) As a general rule, aluminum alloy cylinders that have reached temperatures greater than 350 °F (177 ‘C) shall be condemned as described in this standard. This is because the strenath properties of the aluminum metal material degrade when material temperatures exceed 350 °F (177 °C). The longer the material remains at this or greater temperatures, the greater degradation of the metal, The greater the temperature the cylinder material reaches, the faster and greater the degradation. A combination of temperature and time are critical to the effect heat has on aluminum (or any metallic) cylinder. However, this heating concern is not to be confused with heat exposure. Elevated heat exposure is a different Condition than obvious heat or fire damage. The difference is whether the cylinder material actually reaches an elevated temperature even though the environment could be greater than 350 “F (177 °C). Elevated heat expo- ssure could or could not result in permanent heat damage to the cylinder depending on whether or not the metal ‘material temperature exceeds 350 °F (177 °C). Damaging elevated heat exposure occurs when the cylinder has been subjected to a temperature in the environ- ment that causes the cylinder material to attain temperatures greater than 360 °F (177 “C). When the cylinder material temperature exceeds 350 F (177 °C), the cylinder is damaged and needs to be condemned. ‘Acylinder is not intended for normal use in any environment that would heat the material to temperatures greater than 350 °F (177 °C). The short-term exposures to temperatures greater than 360 °F (177 °C) such as in a firefighting environment do not cause the cylinder material to exceed 350 °F (177 °C), and thus is not cause for cylinder condemnation. For example, a cylinder used within SCBA on a person's back could be exposed to elevated temperatures greater than 350 °F (177 °C) but the material of the cylinder did not reach such a temper- ature and remains safe to fl and use, Such exposures were short and the metal did not get hot. Prolonged unprotected heat exposure to an environment just greater than 350 °F (177 °C) or a short heat expo- sure to an environment of much greater temperatures (over 600 °F [315 *C]) is cause for condemnation If there is any doubt whether a cylinder has been damaged from heat exposure, a properly and diligently per- formed hydrostatic test can determine if the cylinder is fit for service. Any suspect cylinder unable to pass the hydrostatic retest shall be condemned. Any suspect cylinder that passes the hydrostatic retest may be retuned to service if all other requalifcation criteria are satisfiedCompressed Gas Association The Standard For Safety Since www.cganet.com