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Composite Cylinders

USE AND HANDLING IN THE PROPANE INDUSTRY

NOTICE AND DISCLAIMER CONCERNING LIABILITY


The Propane Education & Research Council (PERC) is a non-profit 501(c)6 trade organization authorized by the Propane Education and Research Act of 1996 (PERA), Public Law 104-284. PERC was created to enhance consumer and employee safety and training, to provide for research and development of clean and efficient propane utilization equipment, and to inform and educate the public about safety and other issues associated with the use of propane. PERC is governed by a 21-member Board of Directors appointed by the National Propane Gas Association (NPGA) and the Gas Processors Association (GPA). PERC program beneficiaries include propane retail marketers, producers, transporters, and agricultural cooperatives, as well as representatives of allied service and supply industries (industry members). The recommendations, standards, or recommended practices, as reflected in this document, were developed by independent consultants retained by PERC. While PERC administers the process of obtaining the information, it does not independently test or verify the accuracy of the information or methods used to collect the data that supports the conclusions or recommendations reflected in this document. PERC, NPGA, GPA, and the industry members disclaim any liability for any personal injury, property damage, business losses, or other damages of any nature whatsoever, whether special, indirect, consequential, or compensatory, directly or indirectly resulting from the publication, use, or reliance on this document, or any information, apparatus, method, process, or similar item disclosed in this document. This disclaimer of liability shall apply even if such loss or damage results, in whole or in part, from any acts or omissions of or by any negligence on the part of PERC, NPGA, GPA, or industry members or any persons who contributed to the development of the information contained in this document. PERC, NPGA, GPA, and industry members make no warranty or guaranty as to the accuracy or completeness of any information published in this document. The procedures and information in this document are intended to implement the standards set forth in the documents referenced with capabilities of the personnel and equipment available. It does not create new standards or criteria for compliance. The order of steps in any procedure may or may not be of importance. This material is not sold nor is it a product of any consulting or engineering activity. Users of this document should consult the law of their individual jurisdictions for codes, standards, and legal requirements applicable to them. This document is not intended nor should it be construed to (1) set forth policies or procedures that are the general custom or practice in the propane industry; (2) establish the legal standards of care owed by propane distributors to their customers; or (3) prevent the user from using different methods to implement applicable codes, standards, or legal requirements. By disseminating or publishing this document, PERC is not undertaking to render any professional or other service to or on behalf of any person or entity. PERC, NPGA, GPA, and the industry members are not undertaking to perform any duty owed by any person or entity to any third party. Anyone reading or using this document should rely on his or her own judgment or, as appropriate, should seek the advice of a competent professional in determining the exercise of reasonable care in any and all circumstances. This booklet was developed under a grant by the Propane Education & Research Council. For further information regarding propane safety, visit www.propanesafety.com. 1140 Connecticut Avenue Suite 1075 Washington, D.C. 20036 202.452.9054 www.propanecouncil.org

Table of Contents
Notice and Disclaimer Concerning Liability Purpose of This Document..........................................................................................................1 What Is a Composite Cylinder?................................................................................................2 TYPES OF Composite Cylinders..................................................................................................3 How are Composite Cylinders Marked?.........................................................................4 Special care of composite cylinders.................................................................................5 How Do I Inspect a Composite Cylinder before filling?.....................................5 Visual Inspection Acceptance/Rejection Criteria...................................................6 Examples of unacceptable damage to cylinders and casing......................7 How Do I Fill a Composite Cylinder?................................................................................8 PURGING Composite CylinderS..................................................................................................9 What If I Need to Requalify or Refurbish a Composite Cylinder?...............9 What Safety Information Do I Give to the Customer?...................................10 acknowledgments..........................................................................................................11

Purpose of This Document


The information in this document was developed to provide guidance for propane personnel who have duties related to the safe storage, transportation, handling, and filling of composite cylinders. It will also help in responding to questions from users of composite cylinders. Composite cylinders are different in many ways from steel and aluminum cylinders. Key sections and information in this booklet include: Design and construction features Physical and mechanical characteristics Cylinder specifications and ratings Standards and markings Safety information After reviewing this booklet, the reader should be able to identify what needs to be done when a customer brings a composite cylinder to a facility for initial filling or refilling, and why these steps should be taken.

What Is a Composite Cylinder?


Propane composite cylinders are high-strength containers made from a mixture of fiberglass or carbon fibers and a plastic resin, typically epoxy. The main body of the composite cylinder is translucent, which means that the user can easily see the liquid level in the cylinder and avoid unexpected fuel run-outs. The main body is protected by a hard plastic outer shell. The service/fill valve on a composite cylinder is typically unique to the manufacturer of the cylinder. However, the service and fill connections are identical to those connections on valves used in steel or aluminum cylinders. The end user and the propane filler can use the standard connections for their applications. No adapters are necessary to use or fill composite cylinders. Composite cylinders being manufactured for sale in the U.S. are used for outdoor applications such as barbecue grills and patio heaters, and for industrial applications such as forklifts. Composite cylinders sold in the U.S. are constructed in accordance with U.S. Department of Transportation (DOT) special permits. Cylinders under DOT special permits can be found in two basic designs approved by the DOT: one-piece and two-piece construction. Both types of cylinders include the same type of approved valves, pressure-relief devices, and overfillprevention devices (in some composite cylinders) as found on aluminum and steel propane cylinders.

Plastic Outer Shell Composite Layer Main Body Liquid Level

Composite Cylinder for Outdoor Applications

Features of Composite Cylinders Include:


 Lightweight Composite cylinders weigh 3350% less than steel cylinders that can hold an equivalent amount of propane, and are approximately the same weight as aluminum cylinders.  Visible Gas Level The main body is translucent (see-through), which allows the user to see how much propane is inside.  Non-rusting It will not rust, as can happen with a steel cylinder, since the cylinder is made from plastic and fiberglass.
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Types of Composite Cylinders

One-Piece Construction
The one-piece composite cylinder is currently manufactured by two companies: Ragasco (models pictured above) and Kompozit-Praha. The cylinders are made from tough polymeric and fiberglass materials that are chemical resistant. An outer casing protects the cylinder and the valve.

Two-Piece Construction
The two-piece composite cylinder is currently manufactured by The Lite Cylinder Company as a two-piece main body (top and bottom fitted together). The two halves of each cylinder are wound with fiberglass and then injected with plastic resin. A hard plastic outer casing protects the cylinder and the valve.

How Are Composite Cylinders Marked?


Composite cylinders are marked differently from steel or aluminum cylinders, and are marked according to the requirements in the DOT special permits. Additionally, these permits have different requirements specified for placement of the markings for the manufacturers. For Lite cylinders, each cylinder must be permanently marked in the epoxy coating on the side near the end of the cylinder containing the valve outlet. The marking cannot be a stamping in the filament wrap. The required markings must be at least 1/4" high. For Ragasco and Kompozit-Praha cylinders, the markings must be made on the top face of the cylinder boss by laser etching or by engraving. The required markings must be at least 1/8" high. The DOT special permits for Ragasco and Kompozit-Praha also require that each of their cylinders be permanently and legibly marked: CylINDeR MUST NOT Be STOReD IN AN UNVeNTIlATeD SPACe.
Note: Additional identifying markings, such as corporate logos, are also allowed in the epoxy coating.

ReQUIReD MARKINGS MUST INClUDe


Special permit number

DOT SP14562 0294 012345 XY AB 03 08

DOT-SP14562-0294 012345-XY AB 03-08 Life: 15 years

Service pressure (psig) Serial number and manufacturer identification Inspector mark Date of test and inspection

Example of Required Markings on a Lite Cylinder

Example of Required Markings on a Ragasco Composite Cylinder

Special Care of Composite Cylinders


The care and handling of composite cylinders are different from that of steel and aluminum cylinders. Proper care of composite cylinders include: Do not expose composite cylinders to temperatures higher than 149F (65C). If a composite cylinder is dropped from a distance of four feet or higher, a complete inspection should be performed by qualified personnel. Wash composite cylinders with soap and water. It is important to rinse the soap away after washing. Tar oil, labels, and other foreign matter may be cleaned from the cylinder surface by water-jet cleaning, chemical cleaning, or other suitable methods.

How Do I Inspect a Composite Cylinder Before Filling?


To ensure that a composite cylinder is acceptable for filling or refilling, perform the following steps: 1.  Inspect the cylinder to ensure that the required permanent markings are on the cylinder. 2.  Check the markings for completeness, and make sure that the latest test/ inspection date is no more than five years old.  Visually inspect the cylinder per the cylinder manufacturers recommendations for pre-fill inspections. (See table on page 6 for description of damages and acceptance criteria/rejection limits.) 3.  If any damage is observed that meets or is more severe than the rejection limits, the cylinder must be permanently removed from service. Repair of the cylinder is not authorized.  Removal or replacement of the outer casing can be performed only by personnel who are authorized, in writing, by the manufacturer.

If the latest cylinder test/inspection date is more than 5 years old, it cannot be filled and must be removed from service for requalification. Additionally, any cylinder that is more than 15 years beyond its original test/inspection date must be removed from service, and cannot be requalified for continued service.
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Visual Inspection Acceptance/Rejection Criteria


Damage Type Abrasion Damage or Damage from Cut Description Abrasion damage is caused by wearing, grinding, or rubbing away material by friction. Cuts or gouges are caused by contact with sharp objects in such a way as to cut into the composite, reducing its thickness at that point. Rejection Limits  Depth: more than 10% of composite overwrap thickness, or  Total length of cut(s): more than 50% of the diameter of the cylinder, or  Damaged area: maximum diameter more than 50% of the diameter of the cylinder.

Note: Scratches that do not sever a fiber are not reason for rejection.
Impact damage that has caused surface damage, including delamination, is not acceptable. Impact damage made by a pointed object that has caused delamination and surface damage is not acceptable. A delamination that runs through more than one layer is not acceptable. For a bulge (cavity) internally in the composite overwrap, the maximum diameter of the bulge cannot exceed 10% of the composite thickness. Any bulge combined with outer damage is not acceptable. A delamination that is not in combination with outer damage and not covering more than 30% of the cylinder is acceptable. No fiber strands can be cut.

Delamination and Impact Damage

An inter-laminar delamination is a separation of layers of strands. An intra-laminar delamination is a separation between strands within the same layer. It may appear as a white-ish patch, like a blister or an air bubble, beneath the surface. Impact damage may appear as hairline cracks in the resin or delamination or cuts in the composite.

Chemical Damage

Chemical attack would appear as damage to the resin matrix surrounding the fibers. If affected, typically the cylinder surface feels sticky when touched. A cylinder with a casing that is broken or damaged in such a way that it will not be able to protect the cylinder satisfactorily must be removed from service for maintenance. Examples of such damage are broken foot rings and broken handles.

Chemical attack resulting in damage to the resin matrix surrounding the fibers is not acceptable. The cylinder must be removed from service.

Damage of Casing

Acceptable damage can be, for example, small cracks in the casing. If you cannot establish that the cylinder is unaffected, the cylinder must be removed from service for further investigation. Unacceptable damage is, for example, a broken casing. The cylinder must be removed from service for further investigation.

Heat/Fire Damage of the Casing or Main Cylinder Body

Heat or fire damage is evident by discoloration, scarring, or burning of the composite overwrap, casing, labels, and nonmetallic components of the valve.

Visible damage from heat and/or fire is unacceptable. Per DOT, these cylinders cannot be returned to service.

Source: Ragasco

Examples of Unacceptable Damage to Cylinders and Casing

Damage from abrasion

Damage from cuts

Damage from impact in combination with surface defects

Damage from heat

Casing damage

Casing damage

Photos courtesy of Ragasco

How Do I Fill a Composite Cylinder?


Once a pre-fill inspection of the composite cylinder has been completed and no damage has been observed that requires rejection of the cylinder, the cylinder can be filled with propane. As stated in the DOT special permits, filling of composite cylinders must be consistent with the shipping requirements in the Hazardous Materials Regulations for DOT specification cylinders. In summary, this means that the same local, state, and federal filling regulations and procedures that are used for steel cylinders should be used for filling composite cylinders. Composite cylinders are made of resins that have the ability to generate and store static electricity. Additional safe handling procedures are recommended. When handling cylinders, they should be neutralized with a water spray or antistatic solution before refurbishing, purging, or filling. It is very important when handling composite cylinders to wear static-safe footwear, or to use other means to limit potential hazards associated with static electricity. (For more general information on reducing the risks of static electricity, visit: www.propanesafety.com/Pages/StaticDischarge.aspx) Special Permits on File One of the special provisions included in all three DOT special permits is the following requirement: A current copy of this special permit must be maintained for each facility where the package is offered or reoffered for transportation. Simply, this means that a copy of the manufacturers DOT special permit for the specific composite cylinder filled must be on file at the facility where the fill (or refill) occurs. Go to the web site for the U.S. Department of Transportations Pipeline and Hazardous Materials and Safety Administration (PHMSA) at www.phmsa.dot.gov/hazmat and click on Special Permits and Approvals to obtain full copies of any or all of the special permits. Additional Training The DOT special permits require that each hazmat employee who performs a function subject to the special permits (such as filling or refilling cylinders) must receive training on the requirements and conditions of the permit(s) in addition to the training required by DOT regulations.

Purging Composite Cylinders (prior to the initial fill)


Following the proper purging procedures for composite cylinders is important when handling them. Contact the manufacturer for complete purging guidelines and procedures. Fill By Weight Composite cylinders less than 200 lb. water capacity are required by the DOT to be filled by weight if they are being transported in commerce. Otherwise, they can be filled by volume. Follow the step-by-step methods for setting the scale weight and filling portable cylinders by weight described in the Certified Employee Training Program (CETP), Basic Principles and Practices of Propane, Module 8/Lesson 3. Since filling by weight may be different depending on the cylinder type, contact the manufacturer for complete fill-by-weight instructions.

What If I Need to Requalify or Refurbish a Composite Cylinder?


When you review the markings on the composite cylinder during your pre-fill inspection, you will identify the latest test/inspection date. If more than five years have passed since the last test and inspection, the cylinder cannot be filled. The cylinder must be requalified for continued service. Composite cylinders can be requalified only for five-year service intervals. Unlike steel and aluminum cylinders, requalification of a composite cylinder for an additional five-year period requires both a visual inspection and a proof pressure test. These steps can be performed only at a facility properly equipped and registered under DOT requirements. For steel cylinders, the refurbishing process can involve detergent washing, shot-blasting, and painting of the cylinder. The service valve typically requires some type of protection during this process to avoid damage and protect the pressure-relief valve during the blasting and painting steps. For composite cylinders, the refurbishing process is simple. Because composite cylinders are inherently corrosion resistant, the only step that is necessary for refurbishing is to wash with detergent and water. This can be done by an employee who has received training in propane handling procedures.

What Safety Information Do I Give to the Customer?


Upright Cylinders Make sure that the composite cylinder has a consumer warning label. NFPA 58 requires a consumer warning label for all portable, refillable propane cylinders of 100 lbs. or less. This label includes information on the potential hazards of propane. After filling the composite cylinder for customers, you should follow your companys policies and procedures regarding the distribution of safety information for small cylinder users. Forklift Cylinders After you have supplied full forklift cylinders to your customer, you should advise them that these cylinders can be filled or changed only by trained personnel using proper safety procedures, and that they should follow any and all of their companys procedures relating to propane activities. Note: The filling and handling of forklift cylinders (and all types of cylinders) should follow the procedure requirements set forth in NFPA 58 or by the local authority having jurisdiction.

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Acknowledgments
The authors of this booklet would like to gratefully thank the following people for their valuable assistance, contributions, and comments in the preparation of this document: Mike Caldarera National Propane Gas Association Philip Conty AmeriGas Propane, L.P. Stuart Flatow Propane Education & Research Council Jay Hilliard Revere Gas Bob Jones Ragasco North America Bryan Lewis CHS Propane Jerry Lucas Heritage Propane Darrel Reifschneider The Lite Cylinder Company Carlton Revere Revere Gas Jeff Shaffer Shaffers Bottled Gas Matthew Stevens Inergy Bruce Swiecicki National Propane Gas Association Mike Walters AmeriGas Propane, L.P.

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Propane Education & Research Council 1140 Connecticut Avenue, N.W. Ste. 1075 Washington, D.C. 20036 (202)452-8975

2009 Propane Education & Research Council 7/09

PJS 709

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