Type 3 Cylinder
Inspection Manual
Rev. 08/12
www.cng.us.com
Ladies and Gentlemen:
We appreciate having you as our valued customer.
Please review the Cyli nder Inspection Manual for general inspection and
handling procedure.
Please contact us with any cylinder inspection questions or concerns you may
have that may not be covered in the Cylinder Inspection Manual.
Our contact information is:
CNG cylinders international llc
2331 Sturgis Road
Oxnard, CA 93030
Phone: +1-805-278-8060
Fax: +1-805-278-8090
Email: [email protected]
Web: www.cng.us.com
Sincerely,
Siegfried Rivalta
President
CNG cylinders international
1 / 6
TABLE OF CONTENTS
INTRODUCTION Pg. 1
SCOPE Pg. 1
APPLICABLE DOCUMENTS AND SPECIFICATIONS Pg. 1
DEFINITION OF TERMS Pg. 2
DAMAGE LEVELS Pg. 3
INSPECTION GUIDELINES Pg. 3
TABLE 1 - Damage Levels Pg. 4
CYLINDER DISPOSITION AND DISPOSAL Pg. 5
2 / 6
INTRODUCTION
Composite cylinder technology evolved from the rocket motor industry in the 1960's. Type 3
cylinders have a long, safe history in many different applications. CNG cylinders were
introduced in the early 1980's. CNG Cylinders International (from here on referred to as CNGci)
has raised the bar by developing the technology to manufacture large diameter (over 22")
Type 3 CNG cylinders.
SCOPE
This document provides sufficient details for an experienced, certified inspector to guide them
to examine, assess, repair and approve CNG Cylinders International products for continued
service. This document can not cover all aspects of cylinder inspection. In the event an issue is
encountered that is not covered in this guideline or the other applicable documents referenced
herein, please forward your questions to:
CNG Cylinders International LLC
2331 Sturgis Road
Oxnard, CA 93030
Phone: +1 (805) 278-8060, Fax: +1 (805) 278-8090
Email: [email protected] www.cng.us.com/cylindersafety
APPLICABLE DOCUMENTS AND SPECIFICATIONS
ANSI NGV 2 (latest revision) - American National Standard for Compressed Natural Gas Vehicle
Fuel Containers
FMVSS 304 (latest revision) - Federal Motor Vehicle Safety Standards for Compressed Natural
Gas Containers
CSA B51 (latest revision) - Canadian Standards Association High Pressure Cylinders for On-
Board Storage of Natural Gas as a Fuel for Automotive Vehicles
ANSI/NFPA 52 (latest revision) - CNG Vehicular Fuel Systems
CGA C-2 (latest revision) - Compressed Gas Association Recommendation for Disposition of
Unserviceable Cylinders
CGA C-6.4 (latest revision) - Methods of Visual Inspection of NGV Containers and Installations
3 / 6
DEFINITION OF TERMS
IMPACT: Damage caused by dropping or an impact to the cylinder by
another object
BLUNT IMPACT: High energy localized impact that does not gouge, cut or
perceptibly indent the cylinder. This type of damage may not be
easily identified during visual inspection and caution must be
used during inspection. Vehicle/cylinder history should be
reviewed prior to inspection.
ABRASION: Friction damage caused by wearing, grinding or rubbing away of
the composite material.
CRAZE CRACKING: Hairline cracking of the composite material.
DELAMINATION: Separation of the composite layers.
CUT DAMAGE: Damage caused by a "knife like" object.
COMPOSITE MATERIAL: Structural material composed of load bearing fibers imbedded in
a protective resin matrix.
RESIN: Plastic material in the composite overwrap that bonds the fiber
in place and distributes load
LINER: Aluminum inner portion of the cylinder that is seamless, leak
tight and is the mandrel for the composite material.
PORT (BOSS): The threaded opening(s) for the valve, prd or blank plug.
SERVICE PRESSURE: The settled pressure at 70 F gas temperature in which the
cylinder is considered full. This pressure is indicated on the
cylinder label.
OVERPRESSURIZATION: Pressure that exceeds the settled service pressure.
CONDEMNED: Cylinders that have been over pressurized, damaged beyond
repair limits or have reached their end of service life.
4 / 6
DAMAGE LEVELS
LEVEL 1: The damage is minor and considered normal "wear and tear". Such damage
will have no effect on the safety of the cylinder and its continued use.
LEVEL 2: May be abrasion, severed fibers, cuts or gouges that are deeper or longer than
those in Level 1 (see Table 1, page 4). Additional rework and inspection is
required before placing in service.
LEVEL 3: The damage is such that it cannot be reworked and the cylinder is no longer
acceptable for continued service.
INSPECTION GUIDELINES
Preparation: Surfaces shall be cleaned, shields removed and straps loosened to allow visual
inspection. If cylinder(s) need to be vented to allow for internal inspection, the
depressurization shall be performed by qualified personnel only. Venting shall be performed in
an open area to allow the gas to disperse and to limit the possibility of fire or explosion.
Service History and owner input: Prior to performing the inspection the service history shall be
reviewed and the owner (if present) shall be questioned about any vehicle/cylinder incidents.
Visual inspection: Primary method to detect cylinder/valve/prd damage. Inspector shall be
certified by an accredited agency. Inspector shall look for but not be limited to the following:
dents, cuts, abrasion, heat or fire damage, discoloration, chemical damage, unraveling or
broken fiber and any other suspicious anomaly. Verify the cylinder(s) has not exceeded its life.
Please note: if an observation looks different than normal it is cause for further investigation.
CGA pamphlet C-6.4 shall be used a supplement to this guideline.
Coin tap test: Potential impact damage shall be further evaluated by performing a coin tap
test. This test can aid the inspector to determine if the impact damage is excessive and
requires the cylinder to be removed from service. Using a coin, tap the suspect area and listen
to the sound variation. If the tapping changes from a solid to a deadened or hollow sound the
cylinder shall be removed from service. The inspector shall contact CNGci for additional
information.
5 / 6
TABLE 1 - DAMAGE LEVELS
Damage Levels: Scratch/Cuts/Abrasion Rework
Level 1 0.010" max depth none
3.00" max. length none
Level 2 0.011 - 0.036" max depth inspector rework - see below
3.01" - 5.00" max length inspector rework - see below
Level 3 over 0.036" depth remove from service and condemn
over 5.00" length remove from service and condemn
a) Use a two part room curing epoxy for repairs. Loose fibers may be removed prior to repair as
long as defect limits are not exceeded. Verify acceptability of repair(s) prior to returning the
cylinder(s) to service.
Impact damage:
Impact damage may cause severe structural damage and become a safety hazard. Impact
damage may cause damage within the wall and not be readily visible from the surface of the
cylinder. Known impact areas should be marked and evaluated using the coin tap test. Those
cylinders that exhibit a sound variation shall be removed from service and condemned.
Chemical damage:
Chemical damage will alter the composite surface by: blistering, swelling, softening, etching,
and discoloring or by removing resin. Minor discoloration or etching of the surface is
acceptable as long as the source has been identified and eliminated. Clean the affected area
prior to returning to service. All other levels of chemical attack require the cylinder to be
removed from service and condemned.
Gas leakage:
Cylinders and attachments shall be tested for gas leakage on a periodic basis and any time there
is evidence of leakage. If a cylinder is suspected of or exhibiting leakage it shall be immediately
removed from service. Contact CNGci to report the condition and request additional
information.
6 / 6
Fire and heat damage:
180 F is the maximum operating temperature of our cylinders. Cylinders that see short
duration temperatures (less than 5 minutes and not more than 200 F) exceeding this
temperature are acceptable for service. Cylinder shall be not installed next to the exhaust
system or any other heat generating source. Cylinders that have experienced excessive heat or
fire damage are to be removed from service and condemned.
Non-structural anomalies:
Resin crazing, resin bubbles, excessive resin, cracking noise when filling and fiber gaps on the
dome surfaces are some of the anomalies that are non-structural and will have not affect on
the cylinders integrity. If other anomalies are detected during inspection and are not covered
in this or other associated literature, please contact CNGci for disposition.
Condemned cylinder destruction:
Purge the cylinder with an inert gas prior to drilling as residual compress natural gas may still be
in the cylinder and be a potential safety hazard. Drill two or more 1/2" holes through the
cylinder sidewall. Dispose of the cylinder adhering to the environmental, safety and health
guidelines.
