Cylinder Testing Services
Fire System Services, incorporating National Hydro Cylinder Testing Services, operates and manages an S.A.A. Approved and Licenced Cylinder Test Station Number 720.
INSIDE THE WORKSHOP
We have invested in specialised equipment specificaly for retesting and refilling various types of pressurised cylinders and other devices.
Hydrostatic Pressure Testing Apparatus
The hydrostic pressure testng rig is designed to hydrostaticlly test cylinders and other devices,
and is able of reading the volumetric expansion of the cylinder.
The rig is capable of testing up to 100,000kpa / 14,500psi / 1,000bar.
Air Testing Apparatus
The air testing rig has been designed to test with pure breathable air as the test medium. Occasssionally we are asked to proof test or leak test devices with a medium that contains no fluids or moisture. This apparatus is capable of tests up to 4,000kpa / 580psi / 40bar.
If requested under strictly controlled conditions, at our discretion we may carry out tests up to
40,000kpa / 5,800psi / 400bar.
Low Pressure Testing Pumps
Fire System Services has several low pressure test pumps. These low pressure test pumps are fully portable and versatile, making them ideal for Hydrostatically testing cylinders both in the workshop and in the field. These pumps are capable of testing up to 3,000kpa / 430psi / 30bar.
Carbon Dioxide and Nitrogen Filling Apparatus
We regularly carry out work for the Department of Defence and private industry for retesting and refilling life raft cylinders. Fire System Services has custom engineered and built a reflling appartus, designed to provide either a precise mixture of Carbon Dioxide and Nitrogen for life raft cylinders or an accurate measure of Carbon Dioxide only for Carbon Dioxide cylinders as required.
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Dry Chemical Powder Filling Apparatus
Fire System Services operates two high quality stainless steel dry chemical powder refilling rigs. The use of separate refilling rigs eliminates contamination of ABE and BE powders. These rigs reatomise the dry chemical powder causing it to be extremely stable for fire fighting applications, even after long periods of time. You will notice a grey neck collar fitted to the dry chemical fire extinguisher cylinder being refilled.
These collars are fitted to the cylinder as a QA method following pressure test & refill to prove that the extinguisher has been discharged & devalved. It is impossible to fit these neck collars to a cylinder unless it has been disassembled after discharging for test. Collars are made of embossed uv resistant plastic and are stamped with the month and year of test.
Cylinder Rotator
The Cylinder Rotator was engineered to lift and carry large sized cylinders around the test shop, and also for emptying water after a hydrostatic pressure test. It can rotate a cylinder 360 degrees.
Optical Plus
Using an Optical Plus device we are able to magnify cylinder neck threads by up to 4 times which provides a clear view of any stress or cracks along the cylinder neck or wall during inspection.
Fiber Optic Illuminators
This illuminator casts an extremely bright light into a cylinder, enabling us to view the interior wall for surface corrosion or other defects.
Fiber Optic Illuminators are ideal for internally inspections of Intrinsically Safe environments such as LPG Cylinders.
Video Borescopes
A video Borescopes will allow us to view aspects of cylinders which cannot normally be viewed by the naked eye or by using inspection mirrors.
Visual Plus 3
Endorsed by major cylinder manufacturers, including Luxfer and Catalina, Visual Plus 3 is the best inspection technology you can buy today - and because of its exclusive software and versatile calibration features, Visual Plus 3 will be the equipment of choice for inspecting new aluminum alloys in the future.
AIT has once again advanced the state of the art with Visual Plus 3, the “smartest” eddy-current device available since it eliminates human error and clearly identifies all types of cylinder damage and defects.
More than an upgrade of existing technology, Visual Plus 3 offers all-new computerized features that make it the best tool for inspecting cylinders made from all types of aluminum alloys now in use,
including popular 6061 alloys favored by major global cylinder manufacturers. Visual Plus 3 not only detects cracks… it identifies corrosion, gouges, pits, folds, valleys, tool stops and other types of indications and it shows you the differences among them on five different color-coded graphs, including both linear and three-dimensional views, on a computer screen.
Custom Testing Services
Apart from cylinders, the station is called upon to hydrostatically test & certify variuos items such as:
- Hydraulic lines for the aviation industry ie Helicopter Hydraulic Lines
- Prototype devices designed & manufactured by the DSTO (Weapons Research Division)
- Devices in use by Department of Defence
- Various high pressure hoses for fire fighting applications
- SCUBA & Hooker air lines
- Scientific Pressure Vessels
- NDT such as Dye Penetrine Testing
Stainless Steel Piping tested up to 80,000kpa / 11,603psi / 800bar for the Adelaide Desalination Plant
What Types of Cylinders do we Test?
We are able to hydrostatically test various cylinders from 1mpa up to 33mpa and specialised cylinders as high as 80mpa.
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Air Receiving Cylinders
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Aviation Oxygen Cylinders
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Paintball Cylinders
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Home Brewing Cylinders
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Forklift Cylinders
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Fibre Wrap Cylinders
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Fire Extinguishers
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Refrigerant Gas Cylinders
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Breahting Apparatus Cylinders
Fire System Services delivers services in the field of providing Clean Breathable air fills for both SCUBA and Breahting Apparatus Cylinders. |
SCUBA Cylinders
Sustained Load Cracking (SLC)
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LPG BBQ Cylinders
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LPG Hot Air Balloon Cylinders
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LPG Vechicle Cylinders
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Inflation & Aerospace Cylinders
We are able to test and fill various life raft cylinders, as pictured above the MRM Mirada valves used by the Royal Australian Air Force. |
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Performance Racing Cylinders
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Sampling Cylinders
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Medical Cylinders
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Scientific & Proto Type Pressure Vessels
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CASA Pressurised Cylinder Requirements
Cylinder Testing - Various Methods
Water Jacket Method
The water jacket method for hydrostatic testing consist of loading a water filled cylinder into a sealed chamber (test jacket) filled with water and connected to a calibrated glass tube (burette) Expansion Measuring System (the expansion bowl was invented to replace the burette). The burette or Expansion Bowl is first zeroed and the cylinder is then pressurized to its specified test pressure.
This test pressure is held for a minimum of thirty seconds.
As pressure is applied to "inflate" the cylinder, the cylinder expands and forces water out of the test jacket and up into the Expansion Bowl or burette. After the thirty second test time has elapsed, the Expansion Bowl or burette is read to determine the Total Expansion (in cubic centimeter) of the cylinder under test pressure. The test pressure is released and the cylinder "deflates". As the cylinder shrinks to its approximate original size, water is allowed to drain back into the test jacket from the burette or Expansion Bowl. In most cases the cylinder will not return to its original size, having been slightly stretched by the pressurization process. This stretching is called the Permanent Expansion. The difference between the "Total Expansion" and the "Permanent Expansion" is called the "Elastic Expansion". The Percent Permanent Expansion of the cylinder is determined by the following formula:
Percent Permanent Expansion = (Permanent ExpansionTotal Expansion) X100
When the Percent Permanent Expansion exceeds the predetermined limits for the cylinder being tested, (REE), the cylinder must be condemned and removed from service. A high percent permanent expansion value is an indication that the cylinder metal has lost it's elasticity, or that there has been excessive thinning of the cylinder wall and that the cylinder is no longer safe for use. All test records must be saved and maintained for the duration of the re-qualification Plus (+) stamped cylinders may be filled to an additional 10 percent beyond the service pressure that is stamped on the cylinder shoulder for certain specified gases. The Water Jacket Method of testing compressed gas cylinders is the only hydrostatic test method that qualifies for filling to 10% over service pressure. Star (*) stamping makes the cylinder eligible for an extended ten year re-test interval. The procedures of requirements for plus stamping and star stamping are found in 49 CFR 180.209 (c) for plus stamping and 173.34 (e) (16) for the star. REE values for common cylinder can be found in compressed Gas Association Pamphlet C-5, "Cylinder Service Life, Seamless High Pressure Cylinders".
Proof Pressure Method
The Proof Pressure Test involves pressurizing a cylinder to the appropriated test pressure and then thoroughly inspecting the cylinder, while under pressure, for indications of leaks, deformations, or other indication of possible failure.
Ultrasonic Testing (UT) Method
This method of cylinder testing was introduced in the U.S on exemption basis in 1994. UT differs from other test methods in that the cylinder valve and contents remain intact as no water is used to pressurize the cylinder in this testing procedure.
The UT test involves positioning the cylinder on a rack of rollers that rotate the cylinder, or full immersion of the cylinder in water. Each cylinder is rotated where the entire cylinder sidewall is examined by the inspection probe sensor. This transmits Ultrasonic energy into the cylinder in the form of 'ping-like- sonar soundings from multiple transducers.
A longitudinal beam transducer sends a pulse that echoes straight off the back wall of the cylinder, measuring the time it takes the echo to return, thus measuring the thickness of the cylinder wall. Shear wave or angle beam transducers send sound waves diagonally through the cylinder wall detecting any cracks, pits, or flaws. These 'soundings' are recorded electronically and reviewed to ensure that each cylinder is safe for continued use.
Aluminum cylinders manufactured from 6351 aluminum are required to have an ultrasonic or eddy current neck test every two years to inspect for neck cracks that may have developed over time relating to that grade of aluminum.
This is indicated with E stamped as part of the test stamp. It is sometimes called a "Visual Plus" test after the instrument used to conduct the test.
Direct Expansion Method
This method is the most commonly used with in Australia.
Cylinder Hydrostatic pressure testing is carried out in accordance with Australian Standard 2030.1 & 2337.1 by a Certified Test Station.
The cylinder is then stamped around the neck area indicating the month and year it was tested along with the test station number.
During the direct expansion test, the cylinder is completely filled with water and the test connection is then screwed into the cylinder neck. Water is pumped into the cylinder until the desired test pressure is achieved.
The Volume of water that is pumped into the cylinder to reach the test pressure is measured to determine the Total Expansion. The Volume of the water that is expelled from the cylinder when pressure is released is measured to determine the Permanent Expansion.
Because air has a different compressibility factor than water, air trapped inside the cylinder will cause inaccurate test results so it is very important that the cylinder is completely filled with water to eliminate trapped pockets of air. The weight of the water contained in the cylinder,
the test pressure, test volume (s) and temperature are used to determine the compressibility factor for calculation of the expansion values.
What Actually Happens?
When your cylinder undergoes a visual inspection and hydrostatic test the following will happen. It is picked up and taken to a cylinder test station.
Details of the cylinder are entered on a test certificate: i.e. the cylinder number, the standard to which it was manufactured, working pressure, test pressure and the owner's details.
Visual Inspection
External Inspections
All visual & testing is carried out to Australian Standard 2337.1
An external inspection is carried out looking for damage or alterations that may include bulges, dents, digs, cuts, pits & line corrosions.
Special attention is paid to repainted cylinders as they may have been heat treated or had dents and gouges filled. To carry out this inspection thoroughly the cylinder boot and mesh are removed. Dents, gouges, corrosion or heat treating can all effect the integrity of this high pressure vessel and they can fail test as a result.
The cylinder is then drained and the valve removed,. If in the opinion of the operator the valve requires to be serviced it will usually be serviced at an additional cost. The neck thread and internal space is checked for corrosion, wear, pitting or rust.
Internal Inspections
An internal inspection is then carried out looking for rust, scale, corrosion or oil or any other surface contaminated.
Older aluminum cylinders often fail in this area as the neck thread may have corroded or worn beyond the allowed tolerance, this is an automatic failure under the standard. Aluminum cylinders can also be badly corroded internally especially if salt water has entered the cylinder.
Steel cylinders as we all know can be subject to rust, some brands more than others due to the amount of carbon used in the steel when manufactured.
In particular to scuba cylinders, It needs to be pointed out that rust in steel cylinders is usually a result of carelessness by its user or your fill station. If your cylinder has been filled with moist air from a station that has not been maintaining its filters or compressor adequately rust will occur, oil may also be found if this is the case.
Cylinders found to be rusty or corroded internally and are not beyond repair are brushed using various forms of wire brush attached to a long shaft driven by an electric drill. The residue is cleaned out and rumbling chips inserted into the cylinder, it is then placed on a rumbler that rotates the cylinder at about 90 to 100 rpm for up to eight hours depending on the severity of the corrosion. The cylinder is then filled with water and inverted to assist in removing the chips. It is then cleaned, dried and internally inspected.
This time consuming process removes remaining corrosion and polishes the internal cylinder wall and is an additional cost.
Hydrostatic Testing
If the cylinder passes all the previous inspections it is ready to be hydrostatically tested, when it is filled with water and connected to the test panel. The cylinder is pressurised to no more than 50% of test pressure then released, this is carried out multiple times to check accuracy of the panel and remove air bubbles from the system.
The cylinder is then pressurised to its test pressure (normally 22mpa to 36mpa) and held there for up to one minute. The pressure is slowly released and the expansion measured on a manometer tube. The maximum allowed expansion is the water capacity of the cylinder in kilograms divided by five thousand (1/5000).
The cylinder is disconnected from the test panel and inverted to drain after which it is dried using warm air. After a final internal inspection to ensure proper drying the neck "o"ring is replaced and the valve installed.
The cylinder is then stamped, filled, leak tested at the neck and the test certificate completed. Failed cylinders are destroyed in accordance with the standard.
Mass Test
If the operator was not sure of the expansion he will carry out a tare mass test, or a water capacity mass test.
Tare Mass Test
This is when the cylinder is weighed and the weight compared to the original weight stamped on the neck of the cylinder.
Water Capacity Test
This is when the cylinder is filled with water and weighed and the weight compared to the original water capacity weight stamped on the neck of the cylinder. This is when we can see if the cylinder has received any expansion.
Some Cylinders are high pressure vessels and as such should be handled carefully.
In particular Scuba Cylinders should be washed after use and the valves serviced every twelve months the same as your other valuable gear. In Australia all scuba cylinders are required to be hydrostatically tested every twelve months. Other cylinders are as per chart below.
Cylinder Hydrostatic pressure testing is carried out in accordance with Australian Standard 2030.1 & 2337.1 by a Certified Test Station.
The cylinder is then stamped around the neck area indicating the month and year it was tested along with the test station number.
If the cylinder does not have a current test stamp, it will not, and should not, be filled. The cylinder is in test for twelve months from the date of the test stamp.
Periodic Inspection Testing Dates
As per Australian Standard 2030.5 - 2009
Why Cylinders Should Be Tested
Occasionally we get asked why dose my cylinder have to be tested?
It looks OK, it doesn't get used much, why should I spend my money?
The below incidents tells it all, All pressurised cylinders are dangerous!
Life Boat Explosion
During an inspection of a Company's vessels, the Surveyor showed the attached pictures which were taken after an incident took place on another Company's vessel (he didn't disclose name of the Company or the vessel's name).
As you can see, it occurred due to a gas bottle exploding in a lifeboat during the process of charging it up from the Breathing Apparatus Air Compressor.
The Master of the vessel was in proximity of the lifeboat and he was very seriously wounded. The vessel was 8 years old. The bottle was quite old with different numbers/dates.
E Size O2 CYLINDER EXPLOSION
The following You Tube clip shows you the dangers of pressurised cylinders.
E size O2 Cylinder Explosion
Aluminium Scuba Cylinder Manufacturing
Swiss Valve Removal 'by Lump Hammer' on 300bar cylinder
British Scuba Cylinder Valve knocked off by lump hammer spoof TV advert
CYLINDER SAFETY ALERTS
follow this link to Luxfer web site for safety alerts.
Software - Cylinder Test Certificate
We have available a cylinder test retest certificate in a pdf format.
The certificate can be customised with Logos and relevant information.
It has been designed with Universal test pressure, weights, and other relevant information.
It can be applied for use in any Region.
If you are wanting to know more click on the link Test Certificate
