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AS 2030.52009AS 2030.52009Australian StandardGas cylindersPart 5: Filling, inspection and testing of refillable cylindersThe Standard is downloaded from Standard SharingThis Australian Standard was prepared by Committee ME-002, Gas Cylinders. It was approved on behalf of the Council of Standards Australia on 16 December 2008.This Standard was published on 28 January 2009.The following are represented on Committee ME-002:Australasian Institute of Engineer SurveyorsAustralia New Zealand Industrial Gas AssociationAustralian Chamber of Commerce and IndustryAustralian Gas AssociationAustralian Industry GroupAustralian Steel AssociationDepartment of the Premier and Cabinet, SafeWork SAFire Protection Association of AustraliaInternational Association for Natural Gas VehiclesLPG AustraliaMaterials AustraliaPressure Equipment AssociationVictorian WorkCover AuthorityWelding Technology Institute of AustraliaWorkCover New South WalesThis Standard was issued in draft form for comment as DR 08055.Standards Australia wishes to acknowledge the participation of the expert individuals that contributed to the development of this Standard through their representation on the Committee and through the public comment period.Keeping Standards up-to-dateAustralian Standards are living documents that reflect progress in science, technology and systems. To maintain their currency, all Standards are periodically reviewed, and new editions are published. Between editions, amendments may be issued.Standards may also be withdrawn. It is important that readers assure themselves they are using a current Standard, which should include any amendments that may have been published since the Standard was published.Detailed information about Australian Standards, drafts, amendments and new projects can be found by visiting www.standards.org.auStandards Australia welcomes suggestions for improvements, and encourages readers to notify us immediately of any apparent inaccuracies or ambiguities. Contact us via email at mailstandards.org.au, or write to Standards Australia, GPO Box 476, Sydney, NSW 2001.AS 2030.52009Australian StandardGas cylindersPart 5: Filling, inspection and testing of refillable cylindersOriginated as part of AS CB41931. Previous edition part of AS 2030.11999.Revised in part and redesignated as AS 2030.52009.COPYRIGHT Standards AustraliaAll rights are reserved. No part of this work may be reproduced or copied in any form or by any means, electronic or mechanical, including photocopying, without the written permission of the publisher.Published by Standards Australia GPO Box 476, Sydney, NSW 2001, AustraliaISBN 0 7337 8999 43AS 2030.52009The Standard is downloaded from Standard SharingPREFACEThis Standard was prepared by the Australian members of Joint Standards Australia/ Standards New Zealand Committee ME-002, Gas Cylinders, to supersede (in part) AS 2030.11999, The verification, filling, inspection, testing and maintenance of cylinders for the storage and transport of compressed gases, Part 1: Cylinders for compressed gases other than acetylene. After consultation with stakeholders in both countries, Standards Australia and Standards New Zealand decided to develop this Standard as an Australian Standard rather than an Australian/New Zealand Standard.This edition introduces the following changes:(a)The main title of the AS 2030 series has been changed and simplified to more accurately reflect the scope of the Standard.(b)To clarify the application of the AS 2030 series, the scope of the previous edition of AS 2030.1 has been divided between the new edition of AS 2030.1 and this new Standard, AS 2030.5. This Standard contains requirements previously located in Clauses 5 to 9 of AS 2030.11999.AS 2030.1 applies to all gas cylinders, containing requirements for design, manufacture and inspection (including conformity assessment), requirements to be met prior to the first fill and other issues applicable to all cylinders.AS 2030.5 applies to refillable cylinders (except for acetylene, which remains in AS 2030.2), and contains additional requirements for filling, inspection (periodic and non-periodic) and other issues related to refillable cylinders.(c)Many terms have been re-defined to harmonize with the terminology of the Australian Code for the Transport of Dangerous Goods by Road and Rail (ADG Code), which in turn takes its definitions from UN Model Regulations on the Transport of Dangerous Goods.Of necessity, some terms have definitions which are not the same as the ADG Code. Of these the most significant are the following:(i)This Standard retains the generic term gas cylinder. The corresponding ADG Code term transportable pressure receptacle is generally equivalent to a gas cylinder as defined in this Standard, except that a pressure receptacle may include certain vessels which are built to a general pressure vessel code, whereas such vessels are specifically excluded from the scope of this Standard.(ii)This Standard also retains the generic term welded gas cylinder, rather than the ADG Code term pressure drum, because pressure drum may include general pressure vessels.Appendix C of AS 2030.1 provides a comparison of the definitions used in thisStandard, AS 2030.11999 and the ADG Code.Note that some gases formerly classified as compressed (permanent) are now classified as high pressure liquefied gases.(d)Tables 1 to 4 have been extensively revised to harmonize as far as possible with theADG Code.Complete harmonization is not possible because Australian cylinder standards have, in the past, had a significantly different design philosophy from European cylinder standards. There are two practical differences arising from these philosophical differences:(i)In Europe, cylinders containing compressed gases do not (in general) have burst discs, and may be pressurized in service up to their test pressure. Australian Standards have for many years followed American practice in using burst discs, and these are required to operate at a pressure at or below the test pressure. Logically the maximum operating pressure must be limited to a value below the lowest release pressure of the safety device.(ii)In Europe, cylinders containing liquefied gases have traditionally been fitted with safety devices which release at a pressure between the test pressure and a tolerance above the TP. In Australia, the maximum service pressure is limited to specified percentages (between 80% and 90%) of the maximum test pressure.Therefore, for certain compressed gas mixtures, the maximum filling pressure in Australia may be lower than for a cylinder of equal test pressure authorized for use in Europe, and for liquefied gases to achieve the same filling ratio, the required minimum test pressure in Australia will usually be higher than European practice. (Alternatively, lower filling ratio may be specified for the same test pressure).(e)Requirements for certified gas cylinder test stations (set out in AS 2337.1) have been clarified and some associated terminology has been updated to reflect current usage.The terms normative and informative have been used in this Standard to define the application of the appendix to which they apply. A normative appendix is an integral part of a Standard, whereas an informative appendix is only for information and guidance.Statements expressed in mandatory terms in notes to tables are deemed to be requirements of this Standard.IT SHOULD BE NOTED THAT COMPLIANCE WITH THIS STANDARD MAY NOT NECESSARILY FULFILL ALL LEGAL OBLIGATIONS.19AS 2030.52009CONTENTSPage1SCOPE .5 2REFERENCED DOCUMENTS . 53DEFINITIONS . 54CYLINDER REQUIREMENTS . 65CYLINDER FITTINGS . 66FILLING INSPECTIONS . 87FILLING . 128GAS TRAFFIC CHANGE . 149TEST STATION INSPECTION AND TESTING . 1510MARKING, IDENTIFICATION AND REPAIRS . 17APPENDICESALIST OF REFERENCED DOCUMENTS. 33BMAXIMUM DEVELOPED PRESSURE FOR LISTED GASES. 35CILLUSTRATION OF SKULL MARK AND FIVE-POINTED STAR MARK . 36DSUGGESTED SCHEME OF MARKING FOR SEAMLESS GAS CYLINDERS . 37EREQUIREMENTS FOR FILLING LIQUEFIED GAS CYLINDERS WHERE INSUFFICIENT INFORMATION IS PROVIDED IN CLAUSE 7 ANDThe Standard is downloaded from Standard SharingTABLE 3 OR 4 . 38 Standards Australiawww.standards.org.auSTANDARDS AUSTRALIAAustralian StandardGas cylindersPart 5: Filling, inspection and testing of refillable cylinders1 SCOPEThis Standard specifies requirements for the filling, inspection and testing of refillable gas cylinders for the storage and transport of compressed and liquefied gases, of water capacity ranging from 0.1 kg to 3000 kg.This Standard does not apply to the following: (a)Acetylene cylinders.(b)Closed cryogenic receptacles.(c)Cylinders forming part of aircraft equipment and used solely in aircraft other than as a reference made in a direction pursuant to the Civil Aviation Regulations.(d)Pressure drums or vessels constructed to a pressure vessel standard.The requirements for gas cylinders in fire extinguisher systems and fire extinguishers, apply only where suitable requirements are not given in another Australian Standard.NOTES:1The term cylinder is used interchangeably with gas cylinder in this Standard.2AS 2030.1 sets out requirements for design, verification and manufacturing of all gas cylinders.3AS 2030.2 sets out requirements for compressed dissolved acetylene.4AS 2030.4 sets out requirements for closed cryogenic receptacles (formerly called welded cylinders-insulated).2 REFERENCED DOCUMENTSA list with titles of the documents referred to in this Standard is given in Appendix A.3 DEFINITIONSFor the purpose of this Standard, the definitions in AS 2030.1, and those below apply.3.1 Automatic fill limiter (AFL) valveA device in the filling system which automatically shuts off the filling when a pre- determined level in the gas cylinder has been reached.3.2 Filling ratio definitions3.2.1 Filling ratioThe ratio of the mass of gas to the mass of water at 15C that is filled in a gas cylinder ready for use.3.2.2 Maximum filling ratioThe maximum ratio of the mass of gas to the mass of water at 15C that is permitted to be filled into a gas cylinder by Table 3 or 4 or the cylinder design.The Standard is downloaded from Standard Sharing3.3 Palletized cylinderA cylinder located on a pallet, without any manifolds or piping connections to other cylinders.3.4 Residual pressure valve (RPV)A cylinder valve capable of retaining a specified pressure in a cylinder after its contents have been discharged.NOTE: ISO 15996 provides suitable requirements for such valves.3.5 ShallIndicates that a statement is mandatory in order to comply with this Standard.3.6 ShouldIndicates a recommendation.3.7 Valve with integrated pressure regulation (VIPR)Device intended to be permanently fitted to a gas cylinder connection and comprising a shut-off valve system and pressure reduction system.NOTE: A VIPR may have an unregulated gas outlet connection in addition to the regulated pressure outlet.4 CYLINDER REQUIREMENTSCylinders shall comply with the requirements of AS 2030.1.5 CYLINDER FITTINGS5.1 Valves5.1.1 GeneralCylinder valves shall comply with the relevant part of AS 2473.NOTE: For valves with integral pressure reduction (VIPR), suitable requirements are set out inISO 22435 for industrial VIPR applications, and ISO 10524-3 for medical VIPR applications.5.1.2 Stem threadsThe valve stem (inlet) thread shall be compatible with the appropriate cylinder neck thread as specified in AS 2030.1.5.1.3 Outlet connectionsThe valve outlet connection shall be one of the following in accordance with the intended contents and uses:(a)Medical gases(i)For a non-pressure regulated outlet, the connection specified in AS 2473.3 for the particular gas within the pressure rating defined in that Standard.(ii)For the pressure regulated outlet from a medical VIPR, the outlet connection specified in AS 3840.1.(b)Other gases(i)For a non-pressure regulated outlet, the connection specified in AS 2473.2 for the particular gas and pressure range.NOTE: For compressed gases the pressure range in AS 2473.2 refers to the working pressure, and for high pressure liquefiable gases refers to filling ratios resulting in equivalent maximum developed pressure as for compressed gases. Standards Australiawww.standards.org.au(ii)For the pressure-regulated outlet from an industrial VIPR, the outlet connection specified in either AS 2473.2 or AS 4267 as appropriate.(c)Cylinders imported full for use in Australia, and exported for refilling.The outlet shall be as specified in AS 2030.12008, Appendix B.Outlet connection adaptors immediately downstream of a valve outlet connection are considered to be hazardous due to loss of non-interchangeability between outlets and the risk of leakage and inadvertent separation. Adaptors are used in Australian Department of Defence systems, where close control of the system is provided for. Use of adaptors in other systems shall be avoided.5.1.4 Dedicated filling connectionWhere the valve is fitted with a dedicated filling connection, which is separate from any gas outlet, the filling connection shall be designed to prevent gas withdrawal by the user.NOTE: Dimensions for dedicated filling connections are not specified in this Standard.5.2 Protection of valves5.2.1 GeneralCylinder valves shall be protected against damage from impact by one of the following methods:(a)A cap or guard complying with ISO 11117.(b)A shroud or protection ring permanently attached to the cylinder complying with the drop test requirements of the cylinder Standard, where that Standard requires drop testing of the shroud or protection ring.(c)A shroud or protection ring permanently attached to the cylinder complying with the drop test requirements of ISO 11117.(d)For non-flammable, non-toxic gases, inherent protection by compliance with the impact requirements of AS 2473.1.The form of protection shall not impede escape of discharge from the safety device.5.2.2 Toxic gasesFor cylinders containing toxic gases the valve shall additionally be protected against leakage by a gastight seal rated for the cylinder pressure screwed into the outlet of the valve.5.3 Safety devices5.3.1 GeneralAll cylinders shall be fitted with safety devices, except for the following:(a)Safety devices shall not be fitted to cylinders containing either a medical compressed gas or a toxic gas.(b)Fitment of a safety device to a cylinder is optional for the following: (i)Non-underwater breathing applications (i.e. SCBA).(ii)Where safety device T (see Table 6) is specified in Tables 2, 3 and 4 for the intended contents.(iii)Cylinders in a bundle which utilize one common safety device, in compliance with Clause 5.3.2.Safety devices shall comply with AS 2613.The Standard is downloaded from Standard SharingThe fitment of safety devices shall be in accordance with Tables 2, 3 and 4, as appropriate to the intended contents. There shall be unimpeded escape of discharge from any safety device.NOTE: Requirements for fitment of safety devices to cylinder valves are specified in AS 2473.1.5.3.2 Safety devices on bundlesWhere cylinders for non-flammable non-toxic gas are manifolded together, one common safety device of a rated capacity not less than the sum of the capacities required for all of the manifolded cylinders may be used in place of individual safety devices, provided that there is no shut-off valve between the common safety device and any of the cylinders.5.3.3 Composite gas cylindersA composite gas cylinder shall be fitted with a safety device which has been verified as being of suitable type and performance by testing of the complete cylinder.5.3.4 SCUBA cylindersA bursting disc type safety device with suitable protection against corrosion shall be fitted to all cylinders for SCUBA applications.5.4 Manifolds and valves for bundlesManifold piping and other fittings shall be protected from damage and shall lie wholly within the framework of the bundle.Where cylinders for flammable or toxic gas are manifolded together during transport, there shall be a shut-off valve to isolate each cylinder.6 FILLING INSPECTIONS6.1 GeneralThe cylinder filling inspections shall be carried out only by persons who have the appropriate competence to ensure that each cylinder is safe for continued use.Each cylinder shall be subjected to the following inspections prior to, during and immediately after filling, as appropriate:(a)Verification of cylinder markings (see Clause 6.2).(b)Verification of serviceable condition (see Clause 6.3).(c)Identification of the previous contents, if required (see Clause 6.4).(d)Verification of internal cylinder condition, if required (see Clause 6.5). (e)Verification of integrity of permanent attachments (see Clause 6.6).(f)Verification of the integrity and suitability of the valve and safety device (seeClause 6.7).(g)Verification of correct filling pressure as applicable (see Clause 6.8). (h)Verification of correct filling mass as applicable (see Clause 6.9).(i)Verification of valve protection (see Clause 6.10).(j)Verification of correct identification and labelling (see Clause 6.11).Cylinders filled for use outside Australia shall be subjected to the inspections in accordance with Clause 6.12.Cylinders w
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