Carbon Composite Cylinder Alternative Fuel Cylinders
Contents
1. 13 5 3 3 Inspection AIRNESS ESS LAN NUE UE ees 13 5 4 Recommended equipment 14 5 4 1 inspection Toolse a AA A Ole Cela re de 14 5 4 2 Cut measurement 42 ie essai ease eek ta a 15 5 4 3 Abrasion measurement 16 5 5 Types OF damages sin ed esta dec eed wee 18 5 5 1 Cuts scratches and gouges 18 5 5 2 Fire and heat damao Lire un ae e le Sse eae ie 20 5 9 3 Chemical attack sans webb uses Lacie i 21 594 A AA NI Sa te ene Eee 22 SII ADAR Oea Bodh be eda Ws ihn ee Ss Se M a ee ou 22 5 516 Impactdaimade sles oi eae oi ak eee ada 24 5 6 Table of damage levels 25 OO RED Alt oie ST odes bes whe ee ae ee ee ee eek Sent 26 6 1 Reparto is esa dooce Soh beet hide a Bek 26 6 2 Repair procedur ole EEE 26 6 3 Repairing delamination 29 7 0 Destruction of condemned or expired cylinders 30 3 0 SUNMATY renca A IA AA SAA AAA AA 34 Appendix 1 Cylinder label 35 Appendix 2 AF Cylinder Inspection Form 36 A guide to the use maintenance and periodic inspection of Luxfer carbon composite AF cylinders Page 2 1 0 Introduction Luxfer carbon composite fully wrapped Type 3 and hoop wrapped Type 2 cylinders are among the lightest gas cylinders available for alternative fuel applications These products which meet2. Rubber mounting pads are in place and in good condition PI ee ee o 33 66 Cylinder is firmly restrained by brackets no looseness rocking or cracks O J S All bracket securing bolts are present and tight ee ee 33 67 All bracket and strap bolts are torqued to proper specifications CTC 33 6 7 Mountingbrackets are in good condition and free from bends deformations or damag Mounting bracket area is undamaged nn ee o 383 614 Bracket to vehicle mounting shows no signs of stress o o 33 614 Bracketsandstraps are free from corrosion o 6 19 Cuts gouges and abrasions on the cylinder are less than 0 010 inch in depth oo 78 No Signs of cylinder exposure to fire or extreme heat I So 68 No signs of cylinder damage from an accident ________________k Cylinder is free from impact damage and shows no signs of surface discoloration cracked resin chipping or loose fibers o 33 613 Cylinder service pressure markings are not less than vehicle service pressure 25 613 Cylinderhasnotexceededitsservice life ________ gt k_____ _ o sa Cylinder is properly externally vented this applies only to cylinders enclosed in vehicle oo y 72 Cylinder is free from rust corrosion or etching of the outer surface oo o Sect 7 External paint composite layer and metal surfaces are free from bubbles or bulges
3. 3 Luxfer Gas Cylinders Table of Contents LO TitrOduictiOn usine ein denses 3 1 1 Distribution and proper use of this manual 3 2 0 Product description 4 3 0 Cylinder handling storage and installation 5 SA Hand Le sua E Det ean 5 SIR A A hese eee hah eet hea a Sete aa eae 5 gt Installation it ds ele eee 5 3 3 1 Cylinder installation and protection 5 3 3 2 Motinting Cylinders mesi renal AU AT me A 6 3 3 3 Strap or band belly mounting 6 9 5 4 Neck MOUNU ua a hate A SR SU 7 3 4 Valve and pressure relief PRD installation and removal 7 3 4 1 Valve installations dare a eee ee eae be ees 7 342 Vike Temoval4 ori e ii Bare ee BL 8 3 4 3 Pressure relief device PRD 9 4 0 Cylinder filling fueling and defueling 10 ALO ES Me pare ake Liane BAS eA Bee LR dE di Lane 10 4 1 1 Initial filling fuen 3 cds i do san oe a 10 4 12 Standard llosa emo lo es edad Be eo ave 11 4 2 Dennen nati s ad id Rye Beek Sy hates a eRe AO a aS 11 O INS PECHO NM ici pee a a ae bnew eet 12 NL MOUNUNS INS PCCUON serasa A E EEL BATES CLES 12 5 2 Fuel Systemiinspecuow Lain o Hayes Hoye es Rees 12 5 5 Cylinder inspection ici da Oe oO ee Neue 12 5 53 1 General system inspection 242 saa eee cee mn ei dae nea 13 5 3 2 Periodic recertification inspection
4. 6 0 Repair NOTE It is not possible to repair cylinders showing evidence of chemical attack fire and heat damage Refer to Section 7 0 for instructions on condemning cylinders with these conditions 6 1 Repair tools These tools are needed to repair Level 2 damage left to right 120 grit fine sandpaper a receptacle for mixing epoxy resin a resin applicator two part epoxy resin resin plus cure and a brush that may be needed for removing dust and debris Clean shop rags or heavy duty paper towels are also useful 6 2 Repair procedure For any cylinder with Level 2 damage use the following repair procedure A Clean and sand damaged area with 120 grit fine sandpaper A guide to the use maintenance and periodic Page 26 inspection of Luxfer carbon composite AF cylinders A Wipe off sanding dust A Mix epoxy resin following manufacturer s instructions A guide to the use maintenance and periodic inspection of Luxfer carbon composite AF cylinders A Apply resin to damaged area ensuring that resin is worked fully into any damage Allow to dry following manufacturer s instructions Optional steps to improve cylinder appearance wa dl E Di Optional When the epoxy is fully cured and dried sand the surface again A guide to the use maintenance and periodic Page 28 inspection of Luxfer carbon composite AF cylinders r y Ts poe Optional Apply clear gloss air dry acrylic enamel to the r
5. Valves lines and or pressure relief devices PRD are damage free E O A o o 358 po Fuelandventlines are properly attached to the vehicle pV hiicle history shows no incidents that may possibly have damaged the cylinder Newinspectionstickerhasbeen applied Summary of examination and description of damage and or other adverse findings Repaired or replaced brackets or other components as follows CYLINDER INSPECTION RESULTS check only one A Return cylinder s to service Repair cylinder s as follows Send cylinder s to manufacturer for further inspection as follows REMOVE CYLINDER S FROM SERVICE AND DESTROY Certificate No Inspector s signature
6. On cylinders that have an outer protective fiberglass wrapping disbonding is allowed between the fiberglass and the carbon wrapping beneath it as long as such disbonding is not caused by impact Fire heat Light discoloration No level 2 Evidence of burnt or charred resin Imperial LEVEL 1 LEVEL 2 LEVEL 3 Acceptable Repairable Rejectable Abrasion Any number of flaws Any number of flaws gt 0 01 Multiple flaws gt 0 03 lt 0 01 in depth by any lt 0 03 in depth by any lt 0 05 in depth by gt 1 length length single flaw gt 0 03 in length multiple flaws lt 0 05 inches in depth by 1 lt 0 05 inches in depth by in length any length Cut gouge lt 0 010 inches in depth gt 0 010 inches in depth Impact Small frosted No level 2 Area gt 40 inches dents whitish area major structural damage Delamination Delamination is limited to the outer hoop wrapping only The width of the delamination may not be any wider than the original area of damage from cuts gouges or abrasion above For repair see section 6 3 On cylinders that have an outer protective fiberglass wrapping disbonding is allowed between the fiberglass and the carbon wrapping beneath it as long as such disbonding is not caused by impact Fire heat Light discoloration No level 2 Evidence of burnt or charred resin A guide to the use maintenance and periodic Page 25 inspection of Luxfer carbon composite AF cylinders
7. Prior to filling the cylinder it is important to understand the characteristics and hazards of natural gas including explosion fire and asphyxiation In order to work safely with natural gas do not allow dangerous gas concentrations to form within a working environment Test all systems in a well ventilated area that is free from ignition sources WARNING When working with flammable gases in a confined area always use gas monitoring equipment 4 1 Filling WARNING Always remove all oxidants including air from a cylinder prior to filling the cylinder with flammable gas Be alert to the fact that air may enter the cylinder whenever the cylinder has been vented or exposed to ambient pressure including during initial filling after valve installation or any time the system has been bled to zero pressure 4 1 1 Initial filling fueling WARNING Failure to follow the fuel system manufacturer s instructions on filling may lead to serious injury or death An initial fill is the first pressurization that occurs after the cylinder has been vented or exposed to ambient pressure including initial filling after valve installation or any time the system has been bled to zero pressure The following is a general guideline for removing oxygen including oxygen in air from the cylinder Please refer to the fuel system manufacturer s instructions for detailed procedures Guideline 1 Pressurize the cylinder to at least
8. Elevated heat exposure occurs when the cylinder itself apart from any outer protection has been subjected to a temperature in excess of the glass transition temperature or softening point of the composite material expressed as Tg A composite cylinder is not intended for normal use in any environment resulting in prolonged composite overwrap temperatures in excess of 82 C 180 F Prolonged temperatures in excess of the Tg of the composite may cause discoloration of the resin system This discoloration may range from a light golden caramel color to a deep brownish black burnt appearance Harmless natural aging i e light discoloration of the external coating usually a yellowing over time due to continued direct exposure to sunlight is not the result of harmful temperature exposure Usually the degree and depth of resin discoloration are dependent on the temperature the duration of exposure or a combination of both The higher the temperature or the longer the duration of exposure to a lower temperature the darker the resin system will become If you are uncertain about the cause of resin discoloration contact Luxfer for guidance Fire damage Charring or melting of the composite material decals valves or other attachments is evidence of fire damage Full or partial activation of the PRD is also evidence of fire or excessive heat Flame impingement may result in the resin burning away from the cylinder exterior leaving loose car
9. damage levels in section 5 6 for the maximum area allowed for Level 1 damage Cylinders with Level 1 damage can usually be returned to service 7 A LEVEL 3 Severe damage in which impact has caused a large area of frosting including cuts or abrasion damage to fibers in the cylinder dome liner denting or other major structural damage REJECT and CONDEMN a cylinder exhibiting such damage Refer to table of damage levels in section 5 6 for Level 3 impact cut or abrasion damage limits Reference See table of damage levels in section 5 6 A guide to the use maintenance and periodic Page 24 inspection of Luxfer carbon composite AF cylinders 5 6 Table of damage levels Metric LEVEL 1 LEVEL 2 LEVEL 3 Acceptable Repairable Rejectable Abrasion Any number of flaws Any number of flaws Multiple flaws gt 0 76mm lt 0 3mm in depth by any gt 0 3mm lt 0 76mm in depth lt 1 27mm in depth by length by any length single flaw gt 25 4mm in length mul gt 0 75mm lt 1 27mm in depth tiple flaws lt 01 27mm in X 25 4mm in length depth by any length Cut gouge lt 0 25mm in depth gt 0 25mm in depth Impact Small frosted No level 2 Area gt 258 cm dents whitish area major structural damage Delamination Delamination is limited to the outer hoop wrapping only The width of the delamination may not be any wider than the original area of damage from cuts gouges or abrasion above For repair see section 6 3
10. e When transporting a valved cylinder protect the valve and properly secure the cylinder Never handle cylinders by their fittings valves pressure relief devices or piping 3 2 Storage Store cylinders in a dry environment at temperatures between 40 F and 180 F 40 C and 82 C Protect cylinders from contaminants and damage Short term storage less than six months Prevent the cylinder or assembly from rolling Store at room temperature in a dry place away from chemicals heat sources and corrosive environments Place caps or plugs on cylinder or valve outlets to keep the cylinder and assembly clean and dry and to prevent moisture dust or debris from entering the cylinder Long term storage six months or more Install the valve and O ring according to the valve manufacturer s recommendations see section 3 4 Store the valved cylinder at room temperature in a dry environment and properly protect the valve from damage Store the cylinder with a small amount of positive pressure not more than 3 bar or 40 psi Protect the cylinder from chemicals artificial heat sources and corrosive environments When a valve is not installed place caps or plugs on outlets to keep the cylinder and assembly clean and dry and to prevent moisture dust or debris from entering the cylinder 3 3 Installation 3 3 1 Cylinder installation and protection When the cylinder is installed on a vehicle use shielding to protect the cylinder from dama
11. 5 bar 72 5 psi with a dry inert gas such as nitrogen 2 Vent the cylinder slowly to avoid any condensation in the cylinder or valve 3 Once the system has been vented close the valve to prevent air from re entering the cylinder The cylinder may now be filled with natural gas in accordance with the fuel system manufacturers instructions A guide to the use maintenance and periodic Page 10 inspection of Luxfer carbon composite AF cylinders 4 1 2 Standard fill CAUTION North American users Fill the cylinder such that the settled pressure does not exceed the marked service working pressure at 21 C 70 F All other regions Fill the cylinder such that the settled pressure does not exceed the marked service working pressure at 15 C 60 C 4 2 Defueling WARNING When working with flammable gases in a confined area always use gas monitoring equipment and ground earth all equipment During defueling make sure pressure is sufficiently low that those performing the procedure will not be harmed if gas escapes due to a leak or broken seal However defueling pressure must be slightly higher than atmospheric pressure to stop air from entering the cylinder if a seal is broken Vent gas properly through a flue or flare stack to prevent contaminating the environment and to avoid a potentially hazardous gas accumulation Always make sure that all equipment is properly grounded earthed A guide to the use maintenance
12. NOT USE AFTER 07 2027 inspected after a motor vehicle accident or fire Capacity 200 Liters and at least every 36 months or 36 000 miles whichever comes first for damage and Empty Weight 170 Ib deterioration For visual inspection after a motor 7 a vehicle accident or fire contact Luxfer Gas DOT FMVSS 304 NGV2 00 TYPE 3 Cylinders at 800 764 0366 FOR USE ONLY WITH THE CONTAINER l MANUFACTURER S APPROVED PRD If there is a question about proper use installation or maintenance of this container AND VALVES contact Luxfer Gas Cylinders 3016 Kansas Ave For mor normas ci visi the i ardor Gas Cyl ro ae mind com Rive rside CA 92507 call 800 764 0366 or fax or cal Linier customer service at 800 764 0356 Fax 951 781 6598 951 781 6 508 Appendix 2 AF cylinder inspection form see next page The AF Cylinder Inspection Form may be used as a master for copying additional forms A guide to the use maintenance and periodic inspection of Luxfer carbon composite AF cylinders Page 35 ALTERNATIVE FUEL CYLINDER INSPECTION FORM Date Luxfer _ ee i Manufacturer Pf po Seri O E E e location E E E e Label Serial Applied o e S OE P Pass F Fail o 33 6142 Cylinder and mounting brackets are clean ooo 3 613 Cylinder installation complies with NFPA 52 ___ _ _ _ _ _ Pp 38 44 Minimum 1 2 inch clearance exists around cylinder and 3 8 inch clearance from shield
13. and periodic Page 11 inspection of Luxfer carbon composite AF cylinders 5 0 Inspection Using proper equipment and safety apparatus inspect cylinders routinely to determine whether damage has occurred Thoroughly clean cylinders with a mild soap and water solution before inspecting Do not use solvents harsh cleaners or abrasives Always carefully inspect cylinders if a vehicle has been involved in an accident 5 1 Mounting inspection Ensure that all mounting blocks brackets and other components are in good condition and properly secured If any mountings are loose re tightened them by following procedures specified by the fuel system manufacturer If a mounting is damaged you must conduct a re certification inspection If parts are missing or need replacement please contact the fuel storage system manufacturer 5 2 Fuel system inspection CAUTION Never allow air or debris to enter a cylinder When disconnecting fittings seals during maintenance or inspection make sure that air or debris do not enter through the opening Fuel system inspection includes checking all attached components such as valves tubing end plugs fittings and pressure relief devices During inspection make sure that each device is securely attached If any is loose tighten it in accordance with the fuel system manufacturer s instructions If any component is missing contact the fuel storage system manufacturer and do not put the system back into servi
14. below is an example of a cylinder configured with three PRDs one integrated in the valve a second end plug PRD in the opposite cylinder end and a third L shaped PRD piped from the valve to a central position Additional T shaped PRDs could also be installed in series along the pipe from the valve HE Figure 3 43 A General guidelines that apply to all PRD installations Ensure that threads are undamaged Clean threads thoroughly Dry threads and ensure that the area is free from debris Select the proper O ring or copper crush washer specified by the PRD manufacturer If recommended by the PRD manufacturer apply lubricant to the O ring or copper crush washer Place the O ring or copper crush washer properly on the fitting being careful not to damage the O ring or copper crush washer Thread the fitting into the mating surface e Apply the proper installation torque recommended by the PRD manufacturer A guide to the use maintenance and periodic Page 9 inspection of Luxfer carbon composite AF cylinders 4 0 Cylinder fueling filling and defueling The following section provides standard guidelines only and does not overrule or supersede any applicable regulations industry standards or requirements of fuel storage system manufacturers WARNING Always ground earth the cylinder fuel system or vehicle whenever cylinders are being filled or defueled Failure to do so may result in explosion or fire
15. bon fibers A Fire Damage A guide to the use maintenance and periodic Page 20 inspection of Luxfer carbon composite AF cylinders Inspection method Visually inspect the entire surface of the cylinder for evidence of burnt or charred composite material Also inspect any valves and attachments for evidence of extreme heat Reference Table and repair method Cylinders showing light discoloration of the resin but not showing evidence of extreme heat exposure e g melting of decals charring or heat damage to mounting attachments or PRD activation may be returned to service without repair If you are not sure whether cylinder discoloration is the result of elevated temperature exposure or harmless natural aging contact Luxfer for guidance Immediately remove from service any cylinder involved in a motor vehicle collision or fire Immediately REJECT and CONDEMN any cylinder showing melting or charring of composite material or attachments No repair is possible for this condition See Section 7 0 for procedures on condemning the cylinder 5 5 3 Chemical attack Chemicals including battery acid to which AF cylinders may be exposed may dissolve corrode soften remove or ruin cylinder materials they may also cause bubbling pitting or extreme dulling of the resin or create multiple fractures transverse to the direction of the fiber When solvents are involved the cylinder surface may become sticky when touched e CHE
16. ce 5 3 Cylinder inspection IMPORTANT The Luxfer recommended accept and reject criteria provided in this manual do not replace or supersede any criteria established by regulatory authorities either now or in the future Alternative fuel cylinders are designed and manufactured for a limited design life which is indicated on the cylinder label Always check the label first to ensure that the cylinder has not exceeded its expiration date REJECT and remove from service any cylinder that either lacks a label containing mandatory information or has a label that has become illegible If you can positively determine that Luxfer produced such a cylinder and you know the cylinder serial number contact Luxfer for disposition instructions Inspect for the following conditions during periodic inspection e Cuts scratches and gouges e Fire and heat damage e Chemical attack e Debonding e Delamination e Weathering e Abrasion e Impact damage A guide to the use maintenance and periodic Page 12 inspection of Luxfer carbon composite AF cylinders 5 3 1 General system inspection This inspection usually performed by a driver maintenance person or service technician is a basic visual inspection to ensure that the cylinder and mountings are in good condition The inspection includes as a minimum examining the mounting system cylinder and plumbing as well as checking for gross leaks and damage Perform this inspe
17. chosen mounting system must allow for this expansion and contraction otherwise damage to the cylinder and fuel storage system may occur 3 3 3 Strap or band belly mounting LA B q A L j FT nt ml 4 Figure 3 3 3 Minimum dimensions A 25mm 0 984 B 1 3 of cylinder length CAUTION When using the strap or belly mounting method a strip of rubber must be installed between the cylinder and metal straps to protect the carbon composite exterior of the cylinder The mounting should also be sufficiently flexible to allow for longitudinal cylinder expansion and contraction A guide to the use maintenance and periodic Page 6 inspection of Luxfer carbon composite AF cylinders 3 3 4 Neck mounting Figure 3 3 4 A Visually inspect end mounting blocks regularly for signs of corrosion and premature wear When lubrication of the neck block is required use an aluminum compatible silicon based lubricant 3 4 Valve and pressure relief device PRD installation and removal Use only approved valves and pressure relief devices that comply with applicable standards and regulations e g NGV 2 and ECE R110 A list of approved valves is available at www luxfercylinders com WARNING Do not use valves or pressure relief devices that have not been tested and approved by Luxfer 3 4 1 Valve installation Inspect the valve in accordance with the valve manufact
18. ction at least every three months under normal operating conditions and more frequently during more demanding conditions 5 3 2 Periodic recertification inspection This is an in depth examination of the cylinder mounting system and plumbing for external damage and deterioration including the cylinder surface under the support straps A competent agency or person approved or recognized by applicable regulatory authorities must conduct the inspection in accordance with all applicable regulations and Luxfer specifications Under normal operating conditions perform the inspection every three years or 36 000 miles whichever comes first In addition you must perform a recertification inspection following any accident or fire as well as at the time of any reinstallation This recertification inspection is mandatory under most CNG cylinder and system standards however the prescribed frequency may vary from standard to standard IMPORTANT For the lifetime of a cylinder records of all periodic recertification inspections and testing should be sent to Luxfer along with materials test certificates and inspection reports relating to the manufacture of the cylinder Such record keeping is required by regulatory authorities 5 3 3 Inspection training Luxfer Gas Cylinders offers inspection training either at its AF facilities in Riverside California on site at customer locations or periodically at special training venues watch www luxfercylin
19. ders com for announcements of upcoming training sessions A guide to the use maintenance and periodic Page 13 inspection of Luxfer carbon composite AF cylinders 5 4 Recommended equipment 5 4 1 Inspection tools A mirror and a flashlight are helpful when you are inspecting hard to reach areas Bubbling leak detection fluid is also useful Optional A digital camera can be used to document damaged areas Fill out an inspection report form available from Luxfer If a cylinder is irreparably damaged apply a Danger Failed Cylinder Inspection label to cylinder If the cylinder passes inspection apply a label showing the date of the inspection A guide to the use maintenance and periodic Page 14 inspection of Luxfer carbon composite AF cylinders 5 4 2 Cut measurement A Cut measurement First calibrate the depth gauge to zero on the undamaged cylinder surface A Then measure the depth of the cut A guide to the use maintenance and periodic Page 15 inspection of Luxfer carbon composite AF cylinders 5 4 3 Abrasion measurement A Abrasion measurement Calibrate the depth gauge to zero on the undamaged cylinder surface left then measure the depth of the abrasion at the deepest point right A guide to the use maintenance and periodic Page 16 inspection of Luxfer carbon composite AF cylinders A You may also use a digital depth gauge A guide to the use maintenance and periodic Page 17 inspection
20. e valve is removed inspect it thoroughly Check valve threads for damage and inspect cylinder threads to verify that they are clean cut and undamaged Clean the cylinder O ring gland groove REJECT cylinders with damaged threads REJECT cylinders with O ring gland damage that prevents an effective safe seal A guide to the use maintenance and periodic Page 8 inspection of Luxfer carbon composite AF cylinders 3 4 3 Pressure relief device PRD Use only approved pressure relief devices that comply with applicable standards and regulations e g NGV 2 and ECE R110 Visit www luxfercylinders com for a list of PRDs and proper configurations Some PRDs are integrated into the valve while others must be installed separately If a vent line is required to vent gas away from the cylinder take note that no valves or flow restrictions are allowed anywhere in the inlet or outlet flow path of a PRD Below are sample PRDs installation methods Single PRD configuration Where only a single PRD is required use one of the following configurations approved by Luxfer for the specific cylinder model being considered CNG valve with an integrated PRD Valve with a retrofitted PRD Separate end plug PRD Double PRD configuration Where a double PRD configuration is required use either a CNG valve with an integrated PRD or a valve with a retrofitted PRD in combination with a separate end plug PRD Multiple PRD configuration Figure 3 4 3
21. epaired area 6 3 Repairing delamination A Trim off delaminated fiber at the widest and deepest point Vote Only delamination of the outer hoop wrapping may be repaired The width of the delamination may not be any wider than the original area of damage from cuts gouges or abrasion see section 5 6 above A guide to the use maintenance and periodic Page 29 inspection of Luxfer carbon composite AF cylinders ON 7 AA YE re gt E COS 20 gt 30 ZN 404 ai 60 3 ff Abor 79 3 te 5101 soi A ut a por Ez 10 aa A Measure the width of the clipped segment to make sure that the delaminated area is within acceptable limits for repair A guide to the use maintenance and periodic Page 30 inspection of Luxfer carbon composite AF cylinders A Also measure the thickness of the clipped segment to ensure that it is meets the criteria for repair shown in table 5 6 above A guide to the use maintenance and periodic Page 31 inspection of Luxfer carbon composite AF cylinders T T D hik AN LP A Follow the procedures shown on page 27 above to mix epoxy resin Generously apply resin to the gap left when delaminated fiber was removed from the outer hoop wrapping E A Continue applying resin until the gap left by delamination is completely filled Allow to dry following manufacturer s instructions A guide to the use maintenance and periodic Page 32 inspection of Luxfer carbon composite AF cylind
22. ers A There should be no indentations or low spots in the repaired area which should extend slightly above the original surface of the cylinder A guide to the use maintenance and periodic Page 33 inspection of Luxfer carbon composite AF cylinders 7 0 Destruction of condemned or expired cylinders To destroy condemned or expired cylinders drill a minimum 1 2 inch 13mm hole all the way through the cylinder wrapping and liner so that the cylinder cannot hold gas WARNING Even if completely vented the cylinder will contain a significant amount of residual flammable gas that could ignite Completely purge the cylinder with an inert gas such as nitrogen before destroying it Do not use compressed air to purge the cylinder Always dispose of condemned or expired cylinders in accordance with current NGV 2 guidelines 3 0 Summary 8 1 Care and maintenance ALWAYS Always be alert for leaks with each fill Always keep the threads and cylinder interior dry and free from oil dirt and other contaminants Always fill cylinders with the proper gas Always follow inspection recommendations Always follow the fuel system manufacturer s procedures and recommendations Always follow the valve manufacturer s installation procedures and recommendations Always maintain all accessory equipment in accordance with the manufacturer s recommendations NEVER Never fill a cylinder if it leaks Never fill a cylinder with a defect Never c
23. ge caused by road debris and contact with vehicle components and cargo The preferred shielding is open mesh which not only protects the cylinder but also permits easy reading of cylinder labels To prevent cylinder damage e Avoid direct contact between the shielding and the cylinder e Avoid trapping solid debris or liquids between the shielding and the cylinder e Avoid cylinder contact with vehicle components e g brake lines etc e Avoid exposure to vehicle heat e Avoid exposure to harmful liquids and gases e Avoid prolonged exposure to sunlight A guide to the use maintenance and periodic Page 5 inspection of Luxfer carbon composite AF cylinders 3 3 2 Mounting cylinders Various mounting methods may be used with Luxfer cylinders The mounting method and appropriate mounting hardware are often specified by the fuel system manufacturer and may be supplied by Luxfer While typical the sample mounting methods and parts list shown below are provided for general information only and do not overrule or supersede requirements of fuel storage system manufacturers or specific instructions provided either by system manufacturers or Luxfer for particular mounting configurations Refer to applicable instructions and specifications provided by the fuel system manufacturer before attempting to mount cylinders CAUTION During pressurizing and de pressurizing of a composite cylinder it is normal for the cylinder to expand and contract The
24. ns herein Copyright O 2007 by Luxfer Inc All rights reserved Except as permitted under the U S Copyright Act of 1976 and under provisions cited in paragraph 1 1 above no part of this book may be reproduced in any form without the express written consent of Luxfer Inc Published in the USA by Luxfer Inc 3016 Kansas Avenue Riverside CA 92507 USA 951 684 5110 A guide to the use maintenance and periodic Page 3 inspection of Luxfer carbon composite AF cylinders 2 0 Product description Type 3 AF cylinder Lightweight aluminum liner O Precision machined thread Smooth inert corrosion resistant internal finish High performance carbon fiber overwrap in epoxy resin matrix Type 2 AF cylinder Lightweight aluminum liner Precision machined thread O Smooth inert corrosion resistant internal finish O High performance carbon fiber hoop wrap in epoxy resin matrix A guide to the use maintenance and periodic Page 4 inspection of Luxfer carbon composite AF cylinders 3 0 Cylinder handling storage and installation Use the following guidelines to install Luxfer AF cylinders into vehicles 3 1 Handling To prevent cylinder damage Luxfer recommends the following e Only handle AF cylinders with equipment that will not cause damage e Do not handle cylinders with internal pressure above 3 bar 40 psi e Do not drag drop or roughly handle cylinders e Protect cylinder labels to ensure legibility
25. of Luxfer carbon composite AF cylinders 5 5 Types of damage 5 5 1 Cuts scratches and gouges These are easily spotted on carbon composite cylinders Watch for fiber lifting and unraveling caused by cuts transverse to the direction of the fiber wrapping n Y 1 4 y LL in Fr j J peut Gs r gt i adi lt a s is a a aa n INT a i _ Jf HE CE Vit HUE HN LA NE AURA HH A Level 2 cut Page 18 A guide to the use maintenance and periodic inspection of Luxfer carbon composite AF cylinders A Level 3 cut A Fiber lifting and unraveling Inspection method Inspect cuts scratches and gouges for depth and length Measure depth either with a dial indicator type depth gage or depth caliper Measure length with a graduated scale or ruler Reference Table and repair method The maximum allowable depth and length for this type of damage is found in the table of damage levels in section 5 6 immediately remove from service and condemn any cylinder with unacceptable damage according to this table The appropriate repair method is found in Section 6 1 for cylinders that are capable of being repaired A guide to the use maintenance and periodic Page 19 inspection of Luxfer carbon composite AF cylinders 5 5 2 Fire and heat damage Heat damage Elevated heat exposure which is a different condition than obvious heat or fire damage may or may not result in permanent damage to the cylinder
26. ompletely discharge a cylinder except when you re planning to remove the valve since this can cause moist air to seep into the cylinder Never fill or partially fill a cylinder with any gas not identified on the label Never artificially heat your cylinder Never fill a cylinder that is past its required periodic recertification inspection date Never fill a composite cylinder past its allowable life Never over torque a valve Never remove obscure or alter a manufacturer s labels or stamped markings Never use a cylinder after it has been exposed to an extremely corrosive atmosphere or environment without having it pass the periodic recertification inspection Never use a cylinder that has been involved in a traffic accident or a fire A guide to the use maintenance and periodic Page 34 inspection of Luxfer carbon composite AF cylinders Appendix 1 AF cylinder sample label t CNG ONL Luxfer 3 Luxfer Gas Cylinders Gas Cylinders Luxfer Part Number A2085C 001 WARNING Improper handling use filling storage ee or disposal of this container may result in personal serial Number ADJ 12345 injury death and or property damage Service Pressure 24820 kPa 3600 psig WARNING Do not puncture or drop container Do at 21 C 70 F not modify container in any way Never expose container to temperature exceeding 180 F 82 C Date of Manufacture 7 A 2007 TED y WARNING This container must be visually DO
27. r supersede valve manufacturers torque level recommendations which should be used in preference to the values shown Table 1 Valve torque guidelines VALVE TORQUE VALUE TABLE Min N m fi lb Max N m ft lb 129 05 176 130 339 250 3 4 2 Valve removal In a well ventilated area slowly open the valve to release pressure from the cylinder When the cylinder is completely empty of pressurized gas see section 4 2 remove the valve using proper tools in accordance with the valve manufacturer s guidelines During this process secure the cylinder so that cylinder fibers and the valve are not damaged WARNING If the valve is hard to remove STOP If you suspect for any reason that a valve may be defective do not attempt to remove the valve because a valve that is damaged or not functioning properly may cause you to think erroneously that the cylinder is empty when you do not hear gas being released Handle all valved cylinders even those you think are empty as if they were under pressure To check whether a hard to remove valve is functioning properly add to the cylinder a small amount of the gas specified on the cylinder label to prove that gas actually goes in and out of the valve If the valve works properly during this check fully depressurize the cylinder and then carefully remove the valve If you have questions about valve function or require further instructions contact the valve manufacturer Once th
28. s mee ET a hu ra A Fe y s a g oE _ i ba Ci i a ai i Bi ie Mr ti af nhl 52 a A Chemical attack Inspection method Visually inspect the entire surface of the cylinder for this condition Immediately REJECT and CONDEMN any cylinder with such damage A guide to the use maintenance and periodic Page 21 inspection of Luxfer carbon composite AF cylinders 5 5 4 Weathering Weathering is a change in the surface appearance of composite material or exposed aluminum surfaces resulting from environmental exposure to sunlight road salts and extreme heat and cold Exposure to sunlight can discolor the composite over time this is usually characterized by a yellowish color in the exposed area see Heat and fire damage section 5 5 2 Road salts may corrode exposed aluminum but this does not usually cause damage to composite material Extreme heat or cold may cause mild discoloration of the composite or craze cracking of the surface resin Inspection method Visually inspect the entire surface of the cylinder for weathering Discoloration or craze cracking of the resin is classified as Level 1 damage and does not require repair If corrosion of exposed aluminum is found contact Luxfer Reference Table and repair method 5 5 5 Abrasion Abrasion or localized wearing away of composite material occurs when a cylinder rubs against other components such as mounting brackets the vehicle
29. structure shielding etc y ijt zr LE Ea Gr li ul HIHI A Level 1 abrasion A guide to the use maintenance and periodic Page 22 inspection of Luxfer carbon composite AF cylinders If MADE IN USA tac bull Mi i ii PRE i A Level 2 abrasion een DLT MADE IN USA dl IA uy merma nn ill mi I A Level 3 abrasion Inspection method Visually inspect the entire surface of the cylinder for evidence of abrasion Pay close attention to areas around mounting straps or other attachments Reference Table and repair method Refer to Table 5 6 for damage limits for abrasion Immediately REJECT and CONDEMN any cylinders with unacceptable damage according to this table A guide to the use maintenance and periodic Page 23 inspection of Luxfer carbon composite AF cylinders 5 5 6 Impact damage Impact damage may appear as hairline cracks in the exterior resin cuts abrasion and indentation of the surface of the aluminum liner Inspection method Visually inspect the entire surface of the cylinder for evidence of impact damage Carefully evaluate all impact sites according to the following criteria moza af w y PA fe Te r a EUR NS dl Te NUE A LEVEL 1 Light impact damage that does not require repair It usually consists of a small area where the composite is frosted Where impact results in cuts or abrasion evaluate these features according to the table of
30. the needs of many end users in alternative fuel AF applications offer a lightweight storage solution for compressed natural gas CNG High pressure carbon composite cylinders are designed to be durable for the demanding usage they receive Nevertheless like all compressed gas equipment components cylinders must be well maintained and properly used This guide is intended to assist trained personnel in safely operating valving installing and inspecting Luxfer composite AF cylinders You must be familiar not only with your equipment manufacturer s instructions about properly and safely filling your Luxfer composite cylinders but also with all applicable filling guidelines regulations requirements and laws of all appropriate local and or national authorities and industry organizations Luxfer carbon composite cylinder design development qualification manufacturing and testing are conducted by Luxfer s Alternative Fuel Cylinder Division in Riverside California USA 1 1 Distribution and proper use of this manual This document must be provided to all parties involved in distributing handling installing inspecting and using Luxfer composite AF cylinders The manual may be reproduced to provide sufficient copies for this purpose but its contents must not be altered in any way Luxfer accepts neither responsibility nor liability for consequences resulting from unauthorized alternations to this manual or for failure to follow the instructio
31. urer s recommendations prior to installation Do not install any valve that has not passed such an inspection The valve threads should be free from damage Use appropriate gauges to ensure that threads comply with specifications Ensure that the mating surface on the valve is smooth and free from damage Damaged or distorted valve threads can damage cylinder threads Damage to the mating surface can prevent sealing and can damage the sealing surfaces of the cylinder A guide to the use maintenance and periodic Page 7 inspection of Luxfer carbon composite AF cylinders Check to make sure that the O ring groove and threads in the cylinder are clean and free from damage Install a new O ring on the valve in accordance with the valve manufacturer s recommendations Luxfer recommends lubricating the O ring prior to installation with a lubricant compatible with the O ring material Apply a small amount of aluminum compatible silicon based lubricant to the bottom three valve threads taking care not to apply lubricant to the bottom face of the valve body Only a thin application of lubricant is necessary too much lubricant can cause sealing problems Insert the valve into the cylinder neck and tighten it by hand to make sure threads are properly aligned Then tighten the valve to the torque value recommended by the valve manufacturer Note Valve torque guidelines in the table below are provided for general information only and do not overrule o
Download Pdf Manuals
Related Search