SIST EN 1803:2002

SLOVENSKI STANDARD
SIST EN 1803:2002
01-november-2002
3UHPLþQHSOLQVNHMHNOHQNH3HULRGLþQLQDG]RULQSUHVNXVYDUMHQLKMHNOHQNL]
RJOMLNRYHJDMHNOD
Transportable gas cylinders - Periodic inspection and testing of welded carbon steel gas
cylinders
Ortsbewegliche Gasflaschen - Wiederkehrende Prüfung von geschweißten Gasflaschen
aus Kohlenstoffstahl
Bouteilles a gaz transportables - Contrôles et essais périodiques des bouteilles a gaz
soudées en acier au carbone
Ta slovenski standard je istoveten z: EN 1803:2002
ICS:
23.020.30 7ODþQHSRVRGHSOLQVNH Pressure vessels, gas
MHNOHQNH cylinders
SIST EN 1803:2002 en
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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EUROPEAN STANDARD
EN 1803
NORME EUROPÉENNE
EUROPÄISCHE NORM
February 2002
ICS 23.020.30
English version
Transportable gas cylinders - Periodic inspection and testing of
welded carbon steel gas cylinders
Bouteilles à gaz transportables - Contrôles et essais Ortsbewegliche Gasflaschen - Wiederkehrende Prüfung
périodiques des bouteilles à gaz soudées en acier au von geschweißten Gasflaschen aus Kohlenstoffstahl
carbone
This European Standard was approved by CEN on 8 November 2001.
CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European
Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national
standards may be obtained on application to the Management Centre or to any CEN member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by translation
under the responsibility of a CEN member into its own language and notified to the Management Centre has the same status as the official
versions.
CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece,
Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre: rue de Stassart, 36  B-1050 Brussels
© 2002 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 1803:2002 E
worldwide for CEN national Members.

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EN 1803:2002 (E)
Contents
page
Foreword.3
Introduction .4
1 Scope .5
2 Normative references .5
3 Intervals between periodic inspection and test.6
4 List of procedures for periodic inspection and test.6
5 Identification of cylinder and preparation for inspection and test .7
6 External visual inspection.7
7 Internal visual inspection.8
8 Supplementary tests.8
9 Inspection of cylinder neck.8
10 Pressure test .9
11 Repair of cylinders.9
12 Inspection of valve.10
13 Final operations .10
14 Rejection and rendering cylinder unserviceable.12
Annex A (informative)  Gas cylinders manufactured according to National Regulations.13
Annex B (normative) Inspection periods .15
Annex C (normative)  Description, evaluation of defects and conditions for rejection of welded carbon
steel gas cylinders at time of visual inspection .16
Annex D (normative)  Procedure to be adopted when a cylinder valve is suspected to be obstructed .20
Annex E (normative)  Proof pressure test of gas cylinders.23
Annex F (informative)  Inspection and maintenance of valves and their connections: recommended
procedures.24
Annex G (informative) List of commonly used gases corrosive to cylinder material.25
Bibliography .26
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EN 1803:2002 (E)
Foreword
This document EN 1803:2002 has been prepared by Technical Committee CEN/TC 23 "Transportable gas
cylinders", the secretariat of which is held by BSI.
This European Standard shall be given the status of a national standard, either by publication of an identical text or
by endorsement, at the latest by August 2002, and conflicting national standards shall be withdrawn at the latest by
August 2002.
In this standard the annexes B, C, D and E are normative and the annexes A, F and G informative.
This document has been prepared under a mandate given to CEN by the European Commission and the European
Free Trade Association, and supports the objectives of the framework Directives on Transport of Dangerous
Goods.
This European Standard has been submitted for reference into the RID and/or the technical annexes of the ADR.
Therefore in this context the standards listed in the normative references and covering basic requirements of the
RID/ADR not addressed within the present standard are normative only when the standards themselves are
referred to in the RID and/or the technical annexes of the ADR.
According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following
countries are bound to implement this European Standard: Austria, Belgium, Czech Republic, Denmark, Finland,
France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Spain,
Sweden, Switzerland and the United Kingdom.
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EN 1803:2002 (E)
Introduction
The principal aim of a periodic inspection and testing procedure is that at the completion of the test the cylinders
may be reintroduced into service for a further period of time.
Experience of the inspection and testing of cylinders which is specified in this European Standard is an important
factor when determining whether a cylinder should be returned into service.
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EN 1803:2002 (E)
1 Scope
This European Standard specifies the requirements for periodic inspection and testing of welded, carbon steel
transportable gas cylinders intended for compressed and liquefied gases under pressure, of water capacity from
0,5 l up to 150 l.
NOTE  As far as practicable, this standard may also be applied to cylinders of less than 0,5 l water capacity.
This Standard specifies the requirements for periodic inspection and testing to verify the integrity of such gas cylinders
to be reintroduced into service for a further period of time. It also defines a procedure to qualify existing gas cylinders
for free movement between member states of the European Union (see annex A).
This standard does not apply to periodic inspection and testing of acetylene cylinders or composite (fully wrapped or
hoop-wrapped) steel cylinders.
This standard is primarily for industrial gases other than LPG but may also be applied for LPG. However for dedicated
LPG cylinders, see EN 1440, Transportable refillable welded steel cylinders for liquefied petroleum gas (LPG) –
Periodic requalification prepared by CEN/TC 286 – Liquefied petroleum gas equipment and accessories.
2 Normative references
This European Standard incorporates by dated or undated reference, provisions from other publications. These
normative references are cited at the appropriate place in the text, and the publications are listed hereafter. For dated
references, subsequent amendments to or revisions of any of these publications apply to this European Standard only
when incorporated in it by amendment or revision. For undated references the latest edition of the publication referred
to applies (including amendments).
EN 629-2, Transportable gas cylinders — 25E taper thread for connection of valves to gas cylinders — Part 2: Gauge
inspection.
EN 837-1, Pressure gauges — Part 1: Bourdon tube pressure gauges — Dimensions, metrology, requirements and
testing.
EN 837-3, Pressure gauges — Part 3: Diaphragm and capsule pressure gauges — Dimension, metrology,
requirements and testing.
EN 1089-1, Transportable gas cylinders — Gas cylinder identification (excluding LPG) — Part 1: Stampmarking.
EN 1795, Transportable gas cylinders (excluding LPG) — Procedures for change of gas service.
EN ISO 11114-1, Transportable gas cylinders — Compatibility of cylinder and valve materials with gas contents —
Part 1: Metallic materials (ISO 11114-1:1997).
EN ISO 11114-2, Transportable gas cylinders — Compatibility of cylinder and valve materials with gas contents —
Part 2: Non-metallic materials (ISO 11114-2:2000).
prEN 13322-1, Transportable gas cylinders — Refillable welded steel gas cylinders — Design and construction —
Part 1: Welded steel.
prEN 13322-2, Transportable gas cylinders — Refillable welded steel gas cylinders — Design and construction— Part
2: Welded stainless steel.
EN ISO 13341, Transportable gas cylinders — Fitting of valves to gas cylinders (ISO 13341:1997).
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EN 1803:2002 (E)
3 Intervals between periodic inspection and test
In order to ensure continued safe operation, cylinders shall be periodically submitted to inspection and test in
accordance with annex B. A cylinder shall fall due for a periodic inspection and test on its first receipt by a filler after
the expiry of the interval in annex B.
NOTE  Table B.1 gives a list of the intervals between periodic inspections for some gases which complies with the current
RID/ADR regulations and also gives recommendations which could be subsequently adopted by the RID/ADR regulations.
Provided the cylinder has been subjected to normal conditions of use and has not been subjected to abusive and
abnormal conditions rendering the cylinder unsafe, there is no general requirement for the user to return a gas
cylinder before the contents have been used even though the test interval may have lapsed. However it is
suggested that cylinders are retested within a period not exceeding twice the time interval.
In the case of cylinders used for emergency purposes (e.g. fire extinguishers, breathing apparatus), it is the
responsibility of the person in possession (owner or user) to submit it for a periodic inspection within the interval
specified in annex B or as specified in the relevant cylinder design standard/regulation, if this is shorter.
4 List of procedures for periodic inspection and test
The inspection and test shall be carried out only by competent persons who shall ensure that the cylinders are fit
for continued safe use.
NOTE  A competent person is a person who has the necessary technical knowledge, experience and authority to assess and
approve materials for use with gases and to define any special conditions of use that are necessary. Such a person will also
normally be formally qualified in an appropriate technical discipline.
Each cylinder shall be submitted to periodic inspection and test. The following procedures form the requirements
for such inspection and test, and are explained more fully in later clauses:
- identification of cylinder and preparation for inspection and test (clause 5);
- external visual inspection (clause 6);
- inspection of welds (6.2);
- internal visual inspection (clause 7);
- supplementary tests (clause 8);
- inspection of cylinder neck (clause 9);
- pressure test, proof test only (clause 10);
- repair of cylinders (clause 11);
- inspection of valve (clause 12);
- final operations (clause 13);
- rejection and rendering cylinders unserviceable (clause 14).
Where cylinders are manufactured according to National Regulations and are intended to be qualified under the
Transportable pressure equipment directive (TPED) for free movement and use between member states of the
European Union, additional requirements are specified in annex A.
It is recommended that the above listed tests are performed in the suggested sequence. In particular the internal
visual examination (clause 7) should be carried out before the pressure test (clause 10).
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EN 1803:2002 (E)
Cylinders which fail the inspection or tests shall be rejected (see clause 13). When, after the above tests, doubts
still exist as to the extent of a defect or the condition of a cylinder, then additional tests may be performed in
accordance with clause 8, until such doubts are positively resolved or the cylinder shall be rendered unserviceable.
Some cylinders rejected during periodic inspection and test may be recovered in accordance with annex C.
5 Identification of cylinder and preparation for inspection and test
Before any work is carried out, the relevant cylinder data (e.g. see EN 1089-1) and its contents and ownership shall
be identified.
If contents are identified as hydrogen or other embrittling gases only those cylinders manufactured or qualified as a
hydrogen cylinder shall be used for that service. Such cylinders shall be checked that they are compatible with
hydrogen service i.e. with respect to the maximum tensile strength and internal surface condition (e.g. cylinders
stampmarked according to EN 1089-1 are stamped "H"). All other cylinders shall be withdrawn from hydrogen
service and their suitability checked for their new intended service.
The cylinders shall be depressurized and emptied in a safe, controlled manner before proceeding. Particular
attention shall be given to cylinders containing flammable, oxidizing and toxic gases to eliminate risks at the internal
inspection stage.
Cylinders with incorrect markings, unknown gas contents, or those which cannot be safely emptied of gas, shall be
set aside for special handling.
Cylinders with inoperative or blocked valves may be treated as outlined in annex D. Provided the requirements
above have been complied with, and the cylinder has been depressurized safely, the valve shall be removed.
6 External visual inspection
6.1 Preparation for external visual inspection
Each cylinder shall be cleaned and have all loose coatings, corrosion products, tar, oil or other foreign matter
removed from its external surface by a suitable method, e.g. by brushing, shot blasting (under closely controlled
conditions), water jet abrasive cleaning, chemical cleaning or other suitable methods. Care shall be taken at all
times to avoid damaging the cylinder, or removing excess amounts of cylinder wall.
If fused nylon, polyethylene or a similar coating has been applied and is seen to be damaged, or prevents a proper
inspection, then the coating shall be removed. If the coating is removed by the application of heat, the temperature
of the cylinder shall not exceed 300 °C.
6.2 Inspection procedure
The external surface of each cylinder shall then be inspected for:
a) dents, cuts, gouges, bulges, cracks, laminations or excessive base wear;
b) heat damage, torch or electric arc burns (as defined in Table C.1);
c) corrosion (as defined in Table C.2). Special attention shall be given to areas where water may be trapped.
These include the entire base area, the junction between the body and the foot ring and the junction between
the body and the shroud;
d) weldings. All welds and the areas adjacent to them shall be checked for defects;
e) other defects such as illegible or unauthorized stamp markings, unauthorized additions or modifications;
f) integrity of all permanent attachments;
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EN 1803:2002 (E)
g) vertical stability (if relevant) (as defined in Table C.1);
For rejection criteria, see annex C. Cylinders no longer suitable for future service shall be rendered unserviceable
(as defined in clause 14).
7 Internal visual inspection
Each cylinder shall be inspected internally, using illumination to identify any defects such as those listed in 6.2 a)
and 6.2 c). Precautions shall be taken to ensure that the method of illumination presents no hazards to the tester
whilst performing the operation. Any internal liner or coating which can obstruct optimum internal visual inspection,
shall be removed. Any cylinder showing presence of foreign matter or signs of more than light surface corrosion
shall be cleaned internally under closely controlled conditions by shot blasting, water jet abrasive cleaning, flailing,
steam jet, hot water jet, rumbling, chemical cleaning, or other suitable method. Care shall be taken to avoid
damage to the cylinder. If cleaning is required, the cylinder shall be re-inspected after the cleaning operation.
8 Supplementary tests
Where there is doubt concerning the type and/or severity of a defect found on visual inspection (see clauses 6
and 7), additional tests or methods of examination may be applied, e.g. ultrasonic techniques, check weighing or
other non-destructive tests. Only when all doubts are eliminated may the cylinder be further processed (see
annex C).
9 Inspection of cylinder neck
9.1 Internal neck thread
The internal neck thread of the cylinder shall be examined to ensure that it is:
- clean and of full form;
- free of damage;
- free of burrs;
- free of cracks;
- free of other imperfections.
9.2 Other neck surfaces
Other surfaces of the neck shall also be examined to ensure they are free of cracks or other defects (see annex C).
9.3 Damaged internal neck threads
Where necessary, and where the manufacturer or the competent person confirms that the design of the neck
permits, threads may be re-tapped to provide the appropriate number of effective threads. After re-tapping, the
threads shall be checked by the appropriate thread gauge, (e.g. for 25E threads, in accordance with EN 629-2).
9.4 Neck ring and collar attachment
When a neck ring/collar is attached, an examination to ensure that it is secure and free from thread damage shall
be carried out. Neck rings shall only be changed using an approved procedure. If it is found that any significant
damage to cylinder material has occurred by replacement of the neck ring/collar, the cylinder shall be rendered
unserviceable (see clause 14).
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EN 1803:2002 (E)
10 Pressure test
10.1 General
Each cylinder shall be subjected to a hydraulic or pneumatic pressure test (see 10.2).
10.2 Proof pressure test
10.2.1 General requirements
When carrying out a pressure test, a suitable fluid, normally water shall be used as the test medium. The test shall
be a proof pressure test (see 10.2.2), as appropriate to the design of the cylinder. The test pressure shall be in
accordance with the stamping on the cylinder.
The pressure in the cylinder shall be increased gradually until the test pressure is reached. The cylinder test
pressure shall be held for at least 30 s with the cylinder isolated from the pressure source, during which time there
shall be no decrease in the recorded pressure or any evidence of any leakage. Safety precautions shall be taken
during the test.
10.2.2 Procedure and acceptance criteria
Annex E describes a typical method for carrying out the test.
NOTE  A pneumatic pressure test may be substituted, provided approval from the relevant authority has been obtained. Take
appropriate measures to ensure safe operation and to contain any energy, which is considerably more than that in the hydraulic
test, which can be released.
During the 30 s hold period the pressure as registered on the test gauge shall remain constant.
There shall be no visible leakage or visible permanent deformation on the entire surface of the cylinder. This check
may be made either during the 30 s hold or immediately after the pressure has been released.
Any cylinder failing conforming to with the requirements of this test shall be rendered unserviceable.
11 Repair of cylinders
11.1 Repair of pinholes
If during the pressure test or external visual inspection pinhole leaks are detected in a weld, the cylinder shall be
made unserviceable or repaired by welding. No other repair to pressure containing welds shall be undertaken.
11.2 Other repairs
Any other repairs including dedenting, replacement of foot rings and shrouds may be carried out, provided this will
not impair the integrity of the cylinder. All corrosion products shall be removed prior to repair.
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EN 1803:2002 (E)
11.3 Requirements for repair
11.3.1 Major repairs as defined in 11.1 and 11.2 shall be performed by a competent repairer following an approved
procedure, and taking into account the fabrication and testing requirements of the gas cylinder design standard.
After such repairs, which may involve a high temperature (i.e. greater than 300 ºC), a stress relieving or
normalizing heat treatment shall be performed. The cylinder shall finally be pressure tested in accordance with
clause 10 and inspected as necessary for the intended gas service.
11.3.2 Minor repairs (e.g. reforming damaged shrouds, carrying handles) not involving welding or hot-work on
pressure containing parts may be carried out provided the integrity of the cylinder is not impaired.
12 Inspection of valve
If it is to be re-introduced into service, each valve shall be inspected to verify that it will perform satisfactorily and
ensure gas tightness. An example of a suitable method is given in annex H.
13 Final operations
13.1 Drying, cleaning and painting
13.1.1 Drying and cleaning
The interior of each cylinder shall be thoroughly dried by a suitable method at a temperature not exceeding 300 °C,
immediately after hydraulic pressure testing, such that there is no trace of free water. The interior of the cylinder
shall be inspected to ensure that it is dry and free from other contaminants.
13.1.2 Painting
Cylinders are sometimes re-painted, using paints which require stoving. Plastics coatings may also be reapplied.
Painting or coating shall be applied such that all markings stamped on the cylinder are legible.
In no case shall the temperature of the cylinder exceed 300 °C.
13.2 Re-valving of the cylinder
The valve shall be fitted to the cylinder using a suitable sealing material. An optimum torque necessary to ensure
both a seal between the valve and the cylinder and prevent over-stressing the neck shall be used in accordance
with EN ISO 13341.
The torque applied shall take into consideration the size and form of the threads, the material of the valve, and the
type of sealing material used according to the manufacturer's recommendations. Where the use of
lubricants/sealing material is permitted, only those approved for the gas service shall be used, taking particular care
for oxygen service in accordance with EN ISO 11114-2.
13.3 Check on cylinder tare
This requirement shall only apply to cylinders for liquefied gases. The tare of the cylinders shall be obtained by
weighing on a machine regularly checked for accuracy. The capacity of the weighing machine shall be suitable for
the tare weight of the cylinders.
The tare shall include the mass of the cylinder, valve(s) and all permanent fittings. If the tare of the cylinder differs
from the stamped tare by more than the value shown in Table 1 and is not due to reasons of damage, the original
tare shall be cancelled and the correct tare shall be marked in a permanent and legible fashion in accordance with
EN 1089-1. For welded steel cylinders particular attention shall be paid to the tare weight when replacing any
valves, dip tubes, guards/shrouds and foot rings.
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EN 1803:2002 (E)
Table 1 — Maximum allowable deviation in
cylinder tare weight
Cylinder water Maximum allowable
V
capacity ( ) deviation in tare
weight
lg
0,5
V  5,0 ± 50
5,0
V
20 ± 200
> 20 ± 400
13.4 Stampmarking
After satisfactory completion of the periodic inspection and test, each cylinder shall be permanently marked
according to EN 1089-1 with the present test date followed by the symbol of the inspection body or test station.
13.5 Reference to next test date
The next test date shall be shown in a clearly visible manner by an appropriate method such as a label or a disc
fitted between the valve and the cylinder, indicating the year of the next periodic inspection or periodic inspection
and test.
13.6 Identification of contents
Before the cylinder is reintroduced into service, the cylinder shall be marked according to the intended contents
(e.g. in accordance with EN 1089-2 and EN 1089-3). If painting is required, care shall be exercised in accordance
with 13.1.2. If a change of gas service is involved the requirements of EN 1795 shall be followed.
13.7 Records
Details of the present test shall be recorded by the test station and the following information shall be available:
- owner's name;
- manufacturer's or owner's serial number;
- cylinder tare, where applicable;
- test pressure;
- result of test (pass or fail);
- present test date;
- identification symbol of the inspection body or the test station;
- identification of inspector;
- details of any major repairs made to the cylinder by the inspector.
Additionally, it shall be possible to obtain the following items of information from records, which need not
necessarily be kept on a single file, but will enable a particular cylinder to be traced. These items are:
- cylinder manufacturer;
- manufacturer's serial number;
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EN 1803:2002 (E)
- manufacturing specification;
- water capacity/size;
- manufacturing test date.
14 Rejection and rendering cylinder unserviceable
The decision to reject a cylinder may be taken at any stage during the inspection and test procedure. If it is not
possible to recover a rejected cylinder, it shall, after notifying the owner, be made unserviceable by the testing
station for holding gas under pressure so that it is impossible for any part of the cylinder, especially the shoulder, to
be re-issued into service.
In case of any disagreement, ensure that the legal implication of the contemplated action is fully understood.
One or a combination of the following methods may be employed to render the cylinder unserviceable, after
ensuring that the cylinder is empty and free of gas (see clause 5):
- crush the cylinder, preferably in the shoulder area, using mechanical means;
- burn an irregular hole in the top dome equivalent in area to approximately 10 % of the area of the top dome
or, in the case of a thin-walled cylinder pierce in at least three places;
- cut the neck in an irregular fashion;
- cut the cylinder including the shoulder into two or more irregular pieces;
- burst in a safe manner.
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EN 1803:2002 (E)
Annex A
(informative)
Gas cylinders manufactured according to National Regulations
A.1 Scope
This annex specifies those checks, inspections and tests which shall be performed in order to qualify existing gas
cylinders, manufactured according to National Regulations, to ensure their conformance to the TPED for free
movement and use between all Member States of the European Union.
The annex does not apply to and hence is not necessary for gas cylinders manufactured according to prEN
13322-1 or prEN 13322-2 (see also Directive 84/525/EEC).
A.2 Definitions and symbols



official stamp mark required by the TPED to certify existing gas cylinders conforming to RID/ADR for use
throughout the European Union
A.3 General requirements
A.3.1 The owner of the gas cylinders shall indicate to the inspection body the types and the number of gas
cylinders
...