EN 14912:2005 LPG equipment and accessories Inspection and maintenance of LPG cylinders valves at time of periodic inspection of cylinders M Philippe CARTRY General Manager of PRESTA-GAZ S.A.
DIRECTIVE 2008/98/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 19 November 2008 On waste and repealing of certain Directives (Text with EEA relevance) Extract Article 6 - Definitions 12) prevention means measures taken before a substance material or product become waste, that reduce: a) The quantity of waste, including through re-use of products or the extension of life span of products Extract Article 4 Waste hierarchy 1) The following waste hierarchy shall apply as a priority order in waste prevention and management legislation and policy: a) Prevention b) Preparing for re-use c) Recycling d) Other recovery, e.g. energy-recovery and e) Disposal. SUSTAINABLE DEVELOPMENT a)improved quality and durability of new valve b)en14912 c)only when the first options are not adequate 2
Extract of ADR 2009 Chapter 6.2.4. Requirements for non-un pressure receptacles designed, constructed and tested according standards Depending on the date of construction of the pressure receptacle, the standards listed in the table below shall be applied as indicated in column (5). The requirements of Chapter 6.2 referred to in column (3) shall prevail in all cases If more than one standard is listed as mandatory for the application of the same requirements, only one of them shall be applied, but in full unless otherwise specified in the table below. 3
Reference Title of Document Applicable subsections and paragraphs Mandatory application for pressure receptacles constructed Application authorized for pressure receptacles constructed For periodic inspection and test.. (1) (2) (3) (4) (5) 1803:2002 (Except Annex B) Transportable gas cylinders Periodic inspection and testing of welded steel gas cylinders 6.2.3.5. As from 1 January 2009 Before 1 January 2003.. EN 14189:2003 Transportable gas cylinders Inspection and maintenance of cylinder valves at time of periodic inspection of gas cylinders.. 14912:2005 LPG equipment and accessories Inspection and maintenance of LPG cylinder valves at time of periodic inspection of cylinders 6.2.3.5 As from 1 January 2009 6.2.3.5 As from 1 January 2011 Before 1 January 2003 Before 1 January 2011 4
EN 14912:2005 (e) LPG equipment and accessories Inspection and maintenance of LPG cylinder valves at time of periodic inspection of cylinders 1- Scope This European Standard specifies the requirements for inspection and maintenance of LPG cylinder valves for reuse. It applies when the valves is inspected, repaired or refurbished at the time of periodic inspection of the cylinder. The periodic inspection of cylinders is described in EN1440, EN 14795, EN 14914 and EN 14767. This European Standard may also applied at any other time, for example when maintenance of the valves is necessary * * => also when a valve has to be taken off 5
4- General requirements 4.1 General The valve shall be clean externally to facilitate inspection. Inspection will determinate if: - the valve is suitable for further period of service - a minor repair, major repair or refurbishment is required or - the valve shall be scrapped 6
THE DIFFERENT STEPS OF THE INSPECTION AND MAINTENANCE OF VALVES FOR LPG CYLINDERS Used LPG - valves First sorting First external inspection Cleaning Scrapping Recycling Good and sorted valves Finishing of the tested valves Pressure testing Second external inspection, minor repairs and sorting 7
4.2 Cleaning Contaminants, foreign matter and corrosion products shall be removed from the valve outlet, taking care not to damage any sealing surfaces If any cleaning materials are used, they shall either be : - completely removed after use or - be suitable for and compatible with: - LPG and - materials of construction of: - the valve, - the LPG cylinder and - the associated downstream equipment. 8 8
THE DIFFERENT STEPS OF THE INSPECTION AND MAINTENANCE OF VALVES FOR LPG CYLINDERS Used LPG - valves First sorting First external inspection Cleaning Scrapping Recycling Good and sorted valves Finishing of the tested valves Pressure testing Second external inspection, minor repairs and sorting 9
5. Inspections 5.1 External inspection Valves shall be inspected for: a) Spindles that do not move smoothly or are difficult to turn or seized; b) Bent, deformed, corroded, badly marked, scored or cracked bodies; c) Bent or damaged spindles; d) Cross-threaded, damaged or stripped valve outlet connections; e) Damaged outlet sealing surfaces and/ or any non metallic sealing elements; f) Indications of having be subjected to excessive heat or having been in a fire; g) Foreign matter in visible internal passageways; h) Evidence of abuse or tampering; i) Damage to hand wheels; j) Damage to pressure relief valves; k) Missing parts 10
5. Inspections 5.1 External inspection - photos PAS BON COUP TRANSVERSAL PAS BON VOLANT PLIE 11
5. Inspections 5.1 External inspection - photos PAS BON SOUPAPE ECRASE PAS BON SOUPAPE ABSENTE PAS BON JOINT ABIME (ressortant du logement déchiré écrasé ) 12
5. Inspections 5.1 External inspection - photos 13
5. Inspections 5.2 Additional inspection Valves that have been removed from the cylinder shall have all residual jointing compounds removed from the valve stem thread and the valve bore: They shall be inspected for the following: a) Contaminants, foreign matters and corrosion products; b) Cross-threaded, damaged or stripped stem threads; c) Damaged dip tubes, eduction tubes, sediment tubes and their retaining threads; d) Damage inlet filters; e) Damaged liquid and pressure level indicating devices; f) Damaged overfill prevention devices; g) Damage excess flow devices; h) Missing parts 14
5. Inspections 5.2 Additional inspection PAS BON FILETS ECRASES - ARRACHES PAS BON FILETS ECRASES - ARRACHES 15
6. Maintenance 6.1 Minor repair Damaged outlet non-metallic sealing elements and excess flow prevention devices shall be replaced. If required, gland nuts shall be tightened. The manufacturer s specification shall be followed. Missing parts shall also be replaced. After repair, the valves shall be tested in accordance with 7.2 6.2 Major repairs Actually only reliable on expensive valves (special models) 6.3 Refurbishment 6.3.1 General Valves may only be refurbish if they are designed to be completely dismantled.* * NOT APPLICABLE for Standard German- LPG-valves 16
5. Inspections 5.3 Acceptance criteria Valves inspected in accordance with 5.1 and 5.2 and showing none of the defects shall be tested in accordance with 7.2. (Pressure test) Valves with any of the defects listed in 5.1 and 5.2 shall either be subject to maintenance in accordance with Clause 6 or be scrapped 17
THE DIFFERENT STEPS OF THE INSPECTION AND MAINTENANCE OF VALVES FOR LPG CYLINDERS Used LPG - valves First sorting First external inspection Cleaning Scrapping Recycling Good and sorted valves Finishing of the tested valves Pressure testing Second external inspection, minor repairs and sorting 18
7 Testing 7.1 Refurbished valves 7.1.1 Valves shall be operated open to close to ensure that the operating mechanism is smooth and satisfactory and in accordance with the manufacturer s specification (See EN 13152 and EN 13153) 7.1.2 Valves shall pass a production test in accordance with EN 13152 and EN 13153 as appropriate 7.2 All other valves All other valves shall pass internal and external leak checks e.g. of the gland nut, seat and cylinder neck connection, at the intended operating pressure. This may be carried out during first filling after the valve has been refitted to the cylinder. 19
THE DIFFERENT STEPS OF THE INSPECTION AND MAINTENANCE OF VALVES FOR LPG CYLINDERS Used LPG - valves First sorting First external inspection Cleaning Scrapping Recycling Good and sorted valves Finishing of the tested valves Pressure testing Second external inspection, minor repairs and sorting 20
8 Marking Valves that have undergone refurbishment according to 6.3 shall be permanently marked with at least the 2 last digits of the year of refurbishment and an identification mark traceable to the facility, which carried out the work. Such markings shall not adversely affect the valve. 21
8 Marking Valves that have undergone refurbishment according to 6.3 shall be permanently marked with at least the 2 last digits of the year of refurbishment and an identification mark traceable to the facility, which carried out the work. Such markings shall not adversely affect the valve. ADR 2011, ADR 2013 - Meeting of the informal Working Group of RID/ADR on the extension of the periodicity of periodic testing of steel gas cylinders Munich, 02./03. February 2010 Concerning the today item Testing of valves, some more requirements were asked for in regard of: 1. Responsibility and qualification of the manufacturer or enterprise who tests the valves 2. Traceability 3. Marking of the valves that have been tested according EN 14912:2001 22
Why promoting of the re-use of valves? In line with the Directive 2008/98/CE on Waste and sustainable development, we have to favor manufacturing of good quality valves allowing a longer use on the market. Periodical inspection and the re-use of valves allow to promote this recommendation. (influence of manufacturing quality) 1. A long term experience in several European countries demonstrates a. the majority of defects are defects which should be detected during the filling operations b. Proportionally the difference of the percentage of the rejected valves if they are 1 15 years or older is no significant at all c. Independently how old the valve is, more than 95% of the leakages results from accidental damages or miss-use of the valves/ cylinders. d. In normal conditions of use, LPG valves barely suffer mechanical wear 2. Generally, a leakage on a old valve will appear more gradually than on a new valve (i.e. hidden defect) 3. Actually, dismantled valves less than 15 years old are refitted on re-qualified cylinders without any serious control 4. Extreme competition leads to a reduction of the average quality of new products 23
Safety and responsibility: => As most of the defect valves are linked to a misuse or accidental damages, to improve safety the only solution is to improve the controls at each filling operation. => The periodical inspections / tests of the valves must be limited to identified professionals well equipped, with a confirmed traceability and quality system and assuming the full responsibility of the inspection => The responsibility of such a professional is equivalent to the responsibility assumed by a company doing the periodical requalification of cylinders. In case of major repairs or refurbishment (according EN 14912 Chapter 6.2. or 6.3), the responsibility is equivalent to the one of a manufacturer. 24
Vielen Dank für Ihre Aufmerksamkeit! Philippe CARTRY 25