Transcript Periodic Inspection Period

Emrah T. SAK
March 2013
European Requalification
System
Today’s Outline
 Brief Information About EVAS
 Periodic Inspection in Europe
 General Information About Related EN Standards
 Refurbishment Process
ABOUT EVAS
•
The first LPG cylinder manufacturer of Turkey.
•
One of the biggest LPG cylinder producers in Europe.
•
SHV ENERGY
•
Annually around 2 million cylinders production.
•
Annually around 600.000 cylinders refurbishment.
•
Active in 5 Continets, 49 Countries all around the World
company
Power to Contain World’s Energy
ABOUT EVAS
İstanbul-New Cylinder
Manufacturing
AnkaraRefurbishment
İzmirRefurbishment
Today’s Outline
 Brief Information About EVAS
 Periodic Inspection in Europe
Periodic Inspection Period
Working life of cylinder?
There is no calculated life span for LPG cylinders
Periodic Inspection Period
Average life span of cylinders:
-
In West Europe 41 years
In Turkey 32 years
In UAE (officially )15 years
In Malesia 11 years
Malesia-Cylinder Distribution
EVAS Refurbishment Factories-2012
Number of received cylinders in 2012: 550.000 units
Testing without repair: 87.000 units
Testing with repair: 326.000 units
Scrap: 137.000 units
PRESTAGAZ Statistics-2012
Luxembourgish Company
Number of received cylinders in 2012:
680.000 units from 5 countries
250.000
200.000
Scrapped
36.084
32.897
19.697
14.071
Repaired
6.033
6.393
150.000
Just Testing
100.000
144.339
162.641
155.334
50.000
2.914
4.521
72.041
5.678
4.936
20.697
0
Belgium
Netherlands
France
Switzerland
Germany
Comparison of Turkish and European Data
Turkey
West Europe
10 years
10 or 15 years
Retesting Period:
10%
25%
Distribution of
process:
59%
9%
16%
81%
Scrap
Just Testing
Repaired
Scrapped
Repaired
Assessment before
retesting period:
66%
11%
Average Life Span:
32 years
41 years
Average number of
retesting during
lifespan:
6 times
4 times
Just Testing
Periodic Inspection Period in Europe
- Normally for all cylinders Periodic Inspection Period is 10
years.
- It can be extended to 15 years if followings are fulfilled:
 Cylinder is be owned by and under the responsibility for
checking, filling and maintenance of a competent gas
organisation
Periodic Inspection Period in Europe
11 kg German deposit Cylinder
15 Years Periodic Inspection
11 kg German Nutzung Cylinder
10 Years Periodic Inspection
Periodic Inspection Period in Europe
- Normally for all cylinders Periodic Inspection Period is 10
years.
- It can be extended to 15 years if followings are fulfilled:
 Cylinder is be owned by and under the responsibility for
checking, filling and maintenance of a competent gas
organisation
 there must be an external protection against corrosion
 Cylinder should be filled in accordance with EN 1439
Today’s Outline
 Brief Information About EVAS
 Periodic Inspection in Europe
 General Information About Related EN Standards
European Norms
EN
1440
EN
1439
EN
14912
ADR
EN 1439 - LPG equipment and
accessories. Procedure for
checking LPG cylinders before,
during and after filling
EN 1440 - LPG equipment and
accessories. Periodic inspection
of transportable refillable LPG
cylinders
EN 14912 - LPG equipment and
accessories - Inspection and
maintenance of LPG cylinder
valves at time of periodic
inspection of cylinders
EN 1439
SCOPE
Covers the control operations applied on transportable, refillable
LPG cyliders before, during and after filling.
EN 1439
Segregation
of cylinders
prior to filling
Filling
conditions
Post filling
checks
EN 1439 Segregation of Cylinders before Filling
Clasification
of Cylinders
Cylinders suitable for
filling
Design code/specification
is identifiable;
- tare indication and water
capacity are marked;
- allowed quantity and
identification of the product
are indicated;
- cylinder is within the test
date as determined from
the marked manufacture
date or periodic inspection
date;
- cylinder does not have
defects
-
Cylinders for
periodic
inspection
- Cylinder is out of
test date;
- cylinder cannot be
confirmed to be
within test date.
Cylinders requiring further
assessment
- The indication of tare weight of a
cylinder or required permanent
markings, filled by mass, is missing
or illegible;
- cylinder is faulty or defective, e.g.
dents, fire damage or damage to the
shroud, carrying handles, foot-ring;
- cylinder is found to have visible
corrosion or, with cylinders with a
welded foot-ring, to exhibit corrosion
at the weld;
- valve or pressure relief device (if
fitted) is damaged or has been
previously identified as leaking
EN 1439 Defects for Rejection
EN 1439 Defects for Rejection
EN 1439 Defects for Rejection
EN 1439 Controls During the Filling
Safe filling
quantity
Safe filling
mixture and
quality
Accuracy of
filling
equipment
Filling methods
• Cylinders shall not be filled in excess of the safe
filling quantity.
• Cylinders shall be filled with the appropriate mixture
and quality of LPG.
• Filling equipment and check scales, shall be
checked at least once per working day.
• Filling method should be defined. Cylinders may be
filled by mass, filled by volume or filled to a level.
EN 1439 Post Filling Controls
Check of filled
amount
Action necessary
for over / underfilled cylinders
Final checks
• Each cylinder shall be checked to ensure that the maximum
mass has not been exceeded
• If the cylinder is over-filled, the excess LPG shall be
removed as soon as reasonably practical and the cylinder rechecked.
• If the cylinder is under-filled, the appropriate amount of LPG
shall be added and the cylinder re-checked.
• Cylinders, valves and valve seals shall be checked for
leakage
• Cylinders shall be checked prior to dispatch or storage, for
the correct fitting of valve caps or plugs, valve protection
caps/guards and labeling if required.
EN 1440
SCOPE
Covers the periodic inspection and tests on transportable,
refillable LPG cylinders. Periodic inspections/tests shall be
carried out by a competent person under the control of an
inspection body based on a written scheme and in
accordance with the procedures.
It also consists general frame of repair and it is
requirements.
EN 1440 Procedures for periodic inspection
External visual inspection as per defect definitions (same as EN 1439)
Proof pressure test (hydraulic proof pressure test or, with the agreement of the
competent authority, a pneumatic proof test and leak test)
Internal condition checking
Inspection of threads
Inspection of valves as per EN14912
Today’s Outline
 Brief Information About EVAS
 Periodic Inspection in Europe
 General Information About Related EN Standards
 Refurbishment Process
Refurbishment
Before-After
Refurbishment Process in EVAS
Refurbishment De-Gasing & Valve Removing
EX-ZONE
Detection of liquid gas
Drain and gas recovery
Valve removing
2 Gamma radiation sources
which detect up to 400 gr
gas left in the cylinders.
Emptying bottles and
recovering the gas-in the
gas phase or liquid.
The recovered gas is stored
and re-used. No
atmospheric emissions!
All valves removed are
stored and inspected later
according EN14912 standard
or as per customer specs
Refurbishment Washing & Visual Inspection
Visual Inspection
Internal Washing
Every cylinder is internaly
washed in automatic
carousel
Then cylinders are visually
inspected and separated
either for repairing or
scraping, or conform ones,
send to the finishing hall.
Inspection is realized by
qualified and trained
personnel.
Refurbishment Washing & Visual Inspection
Straighten of FootRing and/or Collar
Separated Damaged
Cylinder
Changing of Foot-ring
or Valve Guard
Refurbishment De-Denting
Blowing
Damaged cylinders are de-dented by
means of pressured air and heating of
dent zone.
Refurbishment
Heat Treatment (stress relieving) at
600-630 oC
Hydrostatic Testing
Shot Blasting
Refurbishment Finishing
Zinc Coating
Painting
Recording
• Retest date,
• Manufacture date
• Manufacturer’s name
Refurbishment Finishing
Valve Fitting
Inkjet Marking
Printing all information regarding
tare weight, test date and next
retest date on the cylinders.
It allows much more legibility
and visibility of all essential
information.
Leakage Test
Refurbishment
Before-After
No Repairable Cylinders
Bulge
Depresed Bung
Lamination
Cut (which exceeds
min. thickness)
Depresed Shroud or Foot-ring
Refurbishment Scrapping
Smashed Cylinders
AIPGL Mexico City-2013
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