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European Requalification System Emrah T. SAK March 2013.

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Presentation on theme: "European Requalification System Emrah T. SAK March 2013."— Presentation transcript:

1 European Requalification System Emrah T. SAK March 2013

2 Today’s Outline  Brief Information About EVAS  Periodic Inspection in Europe  General Information About Related EN Standards  Refurbishment Process

3 ABOUT EVAS The first LPG cylinder manufacturer of Turkey. The first LPG cylinder manufacturer of Turkey. One of the biggest LPG cylinder producers in Europe. One of the biggest LPG cylinder producers in Europe. SHV ENERGY company SHV ENERGY company Annually around 2 million cylinders production. Annually around 2 million cylinders production. Annually around 600.000 cylinders refurbishment. Annually around 600.000 cylinders refurbishment. Active in 5 Continets, 49 Countries all around the World Active in 5 Continets, 49 Countries all around the World

4 Power to Contain World’s Energy

5 ABOUT EVAS İstanbul-New Cylinder Manufacturing Ankara- Refurbishment İzmir- Refurbishment

6 Today’s Outline  Brief Information About EVAS  Periodic Inspection in Europe

7 Periodic Inspection Period Working life of cylinder? There is no calculated life span for LPG cylinders

8 Periodic Inspection Period Average life span of cylinders: -In West Europe 41 years -In Turkey 32 years -In UAE (officially )15 years -In Malesia 11 years Malesia- Cylinder Distribution

9 Number of received cylinders in 2012: 550.000 units Testing without repair: 87.000 units Testing with repair: 326.000 units Scrap: 137.000 units EVAS Refurbishment Factories-2012

10 Luxembourgish Company Number of received cylinders in 2012: 680.000 units from 5 countries PRESTAGAZ Statistics-2012

11 Comparison of Turkish and European Data TurkeyWest Europe Retesting Period:10 years10 or 15 years Distribution of process: Assessment before retesting period: Average Life Span: Average number of retesting during lifespan: 32 years41 years 66%11% 6 times4 times

12 -Normally for all cylinders Periodic Inspection Period is 10 years. -It can be extended to 15 years if followings are fulfilled: Cylinder is be owned by and under the responsibility for checking, filling and maintenance of a competent gas organisation Periodic Inspection Period in Europe

13 11 kg German deposit Cylinder 15 Years Periodic Inspection 11 kg German Nutzung Cylinder 10 Years Periodic Inspection

14 -Normally for all cylinders Periodic Inspection Period is 10 years. -It can be extended to 15 years if followings are fulfilled: Cylinder is be owned by and under the responsibility for checking, filling and maintenance of a competent gas organisation there must be an external protection against corrosion Cylinder should be filled in accordance with EN 1439 Periodic Inspection Period in Europe

15 Today’s Outline  Brief Information About EVAS  Periodic Inspection in Europe  General Information About Related EN Standards

16 EN 1439 - LPG equipment and accessories. Procedure for checking LPG cylinders before, during and after filling EN 1440 - LPG equipment and accessories. Periodic inspection of transportable refillable LPG cylinders EN 14912 - LPG equipment and accessories - Inspection and maintenance of LPG cylinder valves at time of periodic inspection of cylinders European Norms ADR EN 14912 EN 1440 EN 1439

17 Segregation of cylinders prior to filling Filling conditions Post filling checks SCOPE Covers the control operations applied on transportable, refillable LPG cyliders before, during and after filling. EN 1439

18 EN 1439 Segregation of Cylinders before Filling Clasification of Cylinders Cylinders suitable for filling - Design code/specification is identifiable; - tare indication and water capacity are marked; - allowed quantity and identification of the product are indicated; - cylinder is within the test date as determined from the marked manufacture date or periodic inspection date; - cylinder does not have defects Cylinders for periodic inspection - Cylinder is out of test date; - cylinder cannot be confirmed to be within test date. Cylinders requiring further assessment - The indication of tare weight of a cylinder or required permanent markings, filled by mass, is missing or illegible; - cylinder is faulty or defective, e.g. dents, fire damage or damage to the shroud, carrying handles, foot-ring; - cylinder is found to have visible corrosion or, with cylinders with a welded foot-ring, to exhibit corrosion at the weld; - valve or pressure relief device (if fitted) is damaged or has been previously identified as leaking

19 EN 1439 Defects for Rejection

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22 EN 1439 Controls During the Filling Safe filling quantity Cylinders shall not be filled in excess of the safe filling quantity. Safe filling mixture and quality Cylinders shall be filled with the appropriate mixture and quality of LPG. Accuracy of filling equipment Filling equipment and check scales, shall be checked at least once per working day. Filling methods Filling method should be defined. Cylinders may be filled by mass, filled by volume or filled to a level.

23 Each cylinder shall be checked to ensure that the maximum mass has not been exceeded Check of filled amount If the cylinder is over-filled, the excess LPG shall be removed as soon as reasonably practical and the cylinder re-checked. If the cylinder is under-filled, the appropriate amount of LPG shall be added and the cylinder re-checked. Action necessary for over / under- filled cylinders Cylinders, valves and valve seals shall be checked for leakage Cylinders shall be checked prior to dispatch or storage, for the correct fitting of valve caps or plugs, valve protection caps/guards and labeling if required. Final checks EN 1439 Post Filling Controls

24 SCOPE Covers the periodic inspection and tests on transportable, refillable LPG cylinders. Periodic inspections/tests shall be carried out by a competent person under the control of an inspection body based on a written scheme and in accordance with the procedures. It also consists general frame of repair and it is requirements. EN 1440

25 Inspection of valves as per EN14912 Inspection of threads Internal condition checking Proof pressure test (hydraulic proof pressure test or, with the agreement of the competent authority, a pneumatic proof test and leak test) External visual inspection as per defect definitions (same as EN 1439) EN 1440 Procedures for periodic inspection

26 Today’s Outline  Brief Information About EVAS  Periodic Inspection in Europe  General Information About Related EN Standards  Refurbishment Process

27 Before-After Refurbishment

28 Refurbishment Process in EVAS

29 Refurbishment De-Gasing & Valve Removing EX-ZONE Detection of liquid gas 2 Gamma radiation sources which detect up to 400 gr gas left in the cylinders. Drain and gas recovery Emptying bottles and recovering the gas-in the gas phase or liquid. The recovered gas is stored and re-used. No atmospheric emissions! Valve removing All valves removed are stored and inspected later according EN14912 standard or as per customer specs

30 Internal Washing Every cylinder is internaly washed in automatic carousel Refurbishment Washing & Visual Inspection Visual Inspection Then cylinders are visually inspected and separated either for repairing or scraping, or conform ones, send to the finishing hall. Inspection is realized by qualified and trained personnel.

31 Separated Damaged Cylinder Refurbishment Washing & Visual Inspection Straighten of Foot- Ring and/or Collar Changing of Foot-ring or Valve Guard

32 Blowing Damaged cylinders are de-dented by means of pressured air and heating of dent zone. Refurbishment De-Denting

33 Heat Treatment (stress relieving) at 600-630 o C Refurbishment Hydrostatic Testing Shot Blasting

34 Zinc Coating Refurbishment Finishing Painting Recording Retest date, Manufacture date Manufacturer’s name

35 Valve Fitting Refurbishment Finishing Inkjet Marking Printing all information regarding tare weight, test date and next retest date on the cylinders. It allows much more legibility and visibility of all essential information. Leakage Test

36 Before-After Refurbishment

37 No Repairable Cylinders BulgeDepresed Bung Lamination Cut (which exceeds min. thickness) Depresed Shroud or Foot-ring

38 Smashed Cylinders Refurbishment Scrapping

39 THANK YOU! AIPGL Mexico City-2013


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