3.2.5

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: • DOT requirements for inspecting & requalifying cylinders in • LP-gas service • (2) Procedures for visually inspecting & requalifying DOT cylinders in LP-gas service

2. 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. DOT Definitions

4. DOT Definitions

5. DOT Definitions

6. 49 CFR § 180.215 sets out DOT requirements for cylinder requalification reports and record retention. DOT Required Requalification Records Facility Records • Current copies of DOT regulations applicable to cylinder requalification done at the facility • A copy of Compressed Gas Association (CGA) or American Society for Testing and Materials (ASTM) standards applicable to cylinder requalification done at the facility • Current requalifier identification number (RIN) issuance letter (if applicable)

7. DOT Required Requalification Records Facility Records The person who performs the requalification must maintain daily records of visual inspections and pressure tests until either: • the expiration of the requalification period (5 years for external visual inspections), or • until the cylinder is again requalified, whichever occurs first.

8. DOT Required Requalification Records Facility Records Requalification record pages for external visual inspections must document the following: • Date of requalification • DOT specification number • Actual dimensions • Result of visual inspection • Rejection or Condemnation • Cylinder serial number • Marked (service) pressure • Manufacturer’s name or symbol, • if present • Disposition

9. Valid for 5 years from the date Valid for 5 years from the date Valid for 5, 7 or 12 years from the date, depending on the meaning of “x” V10001 0604 E V10001 0604 E 0604 E V10001 Requalification Markings

10. 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. Requalification Methods External Visual Inspection– The inspection must conform to Compressed Gases Association (CGA) standards. “E” requalification mark (5-years)

12. External Visual Inspection Procedures Figure 2. Requalification Periods for DOT Cylinders

13. OK Indicates the cylinder has passed. RM Indicates 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. SC Indicates the cylinder has failed a particular step(s) and must be scrapped or condemned. One of the following marks should be used for “Disposition”: External Visual Inspection Procedures

14. External Visual Inspection Procedures

15. External Visual Inspection Procedures Figure 3. General Distortion:Bulge in Shoulder of Cylinder

16. External Visual Inspection Procedures Figure 4a. Measuring for Bulge or Distortion

17. External Visual Inspection Procedures Figure 4b. Measuring for Bulge or Distortion

18. External Visual Inspection Procedures Figure 5. Damaged Neck: Leaning Cylinder Valve

19. External Visual Inspection Procedures Figure 6. Neck Ring Damage on Motor Fuel Cylinder

20. External Visual Inspection Procedures

21. External Visual Inspection Procedures

22. External Visual Inspection Procedures Figure 9. Pit Gauge Measuring Crevice Corrosion

23. External Visual Inspection Procedures

24. External Visual Inspection Procedures 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. 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.