7 3 1 1 1 0 2 F . o N l e b a L r e v o C
007227
CARBON DIOXIDE AND NITROGEN CARTRIDGES Field Inspection and Refill Manual
REVISION INDEX 4-15-11 REV. 1
DATE 7-23-10 7-23-10
7-23-10
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Revision Record page started at manual revision 2 CGA C-6 – 2001 – See Introduction page for more information
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CGA P-22 – 1995 – See Introduction page for more information
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49 CFR – See See Introduction page for more information
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ANSUL CO2 and N2 Cartridge Recharging Equipment List
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Indicates revised information. Indicates change in page sequence.
TABLE OF CONTENTS 4-15-11 Page 1
SECTION ________
PAGES ______
SECTION ________
PAGES ______
1. INTRODUCTION
1-1
11. APPENDIX
11-1 – 11-5
2. CARTRIDGE INSPECTION AND REFILL OVERVIEW
2-1
3. EQUIPMENT
3-1 – 3-2
Cartridge Specification Table – CO2 Expellant
11-1
Cartridge Specification Table – N2 Expellant
11-2
Temperature Correction Charts
11-3
Cartridge Test Tank – Drawing No. 819
11-4
Ounces-To-Grams Conversion Table
11-5
Cartridge Refilling Equipment
3-1
Inspection Gauges
3-1
Cartridge Test Tank
3-2
Carbon Dioxide Supply
3-2
Nitrogen Supply
3-2
ANSUL Technical Bulletin No. 31, Form No. F-80261, “Carbon Dioxide Cartridges”
4-1
ANSUL Technical Bulletin No. 34, Form No. 80195, “Use and Refilling of ANSUL Gas Cartridges”
Safety
4-1
Maintenance
4-1
ANSUL Technical Bulletin No. 50, Form No. F-81301, “Hydrostatic Retest Requirements for ANSUL Hand Portable and Wheeled Fire Extinguishers”
4. SAFETY AND MAINTENANCE RECOMMENDATIONS
5. PRE-FILLING INSPECTION PROCEDURES
5-1 – 5-2
Purpose
5-1
General Inspection
5-1
Using Cartridge Gauges
5-1 – 5-2
6. FILLING CARBON DIOXIDE CARTRIDGES
6-1 – 6-4
Equipment Setup
6-1
Cartridge Refill Procedure
6-2 – 6-4
7. FILLING NITROGEN CARTRIDGES SMALLER THAN 23 FT 3 (0.7 m3)
7-1 – 7-4
Equipment Setup
7-1
Cartridge Refill Procedure
7-2 – 7-4
Nitrogen Supply Cylinder
7-4
8. FILLING 23/55 FT3 (0.7/1.6 m3) NITROGEN CARTRIDGES
8-1 – 8-3
Equipment Setup
8-1
Booster Pump Specifications
8-1
Cartridge Refill Procedure
8-1 – 8-3
9. LEAK TESTING AND PAINTING
9-1
Leak Testing
9-1
Painting Cartridges Smaller Than 23 ft3 (0.7 m3)
9-1
Painting 23/55 ft3 (0.7/1.6 m3) Cartridges
9-1
Final Inspection and Marking
9-1
10. OUT-OF-SPEC- CARTRIDGES
10-1
12. REFERENCES
SECTION 1 – INTRODUCTION 4-15-11 Page 1-1 REV. 2
INTRODUCTION This manual is intended to be used by only those companies which have been authorized by Tyco Fire Protection Products to refill ANSUL Carbon Dioxide and Nitrogen cartridges. This manual does not apply to other manufacturersʼ cartridges. This manual may not be copied or reproduced for any reason. For safety and quality, this manual is intended for use only by qualified personnel trained and familiar with cartridge filling operations. The authorized cartridge refilling company is responsible for maintaining the proper up-to-date technical publications associated with filling pressure vessels. The technical publications are as follows: 1. Compressed Gas Association Pamphlets – CGA C-6: Standards for Visual Inspection of Steel Compressed Gas Cylinders – CGA P-15: Filling of Industrial and Medical Nonflammable Compressed Gas Cylinders – CGA P-2: The Responsible Management and Disposition of Compressed Gases and their Cylinders 2. Code of Federal Regulations – 49 CFR – Transportation – Transport Canada 3. National Fire Protection Association Standards – NFPA 10
TYCO FIRE PROTECTION PRODUCTS ONE STANTON STREET MARINETTE, WI 54143-2542 +1-715-735-7411
Copyright ©2011 Tyco Fire Protection Products All rights reserved. Form No. F-8986-03
SECTION 2 – CARTRIDGE INSPECTION AND REFILL OVERVIEW 4-15-11 Page 2-1 REV. 1
CARTRIDGE INSPECTION AND REFILL OVERVIEW !
WARNING
To lessen the risk of serious personal injury and to better assure the proper results when filling ANSUL cartridges, the procedures set forth in this manual must be followed in the proper sequence. The following procedures have been established to provide a uniform method for the processing of ANSUL carbon dioxide and nitrogen cartridges returned for refill. Strict adherence to the recommended practices and use of the recommended equipment will help to assure the safety of those handling the cartridges and the sale of only those cartridges which meet specifications. The procedure has been divided into eight sections and must be followed in the sequence listed below: SECTION 1 – EQUIPMENT SECTION 2 – SAFETY AND MAINTENANCE SECTION 3 – INSPECTION PROCEDURES (Before Filling Cartridges) SECTION 4 – FILLING CARBON DIOXIDE CARTRIDGES SECTION 5 – FILLING NITROGEN CARTRIDGES SMALLER THAN 23 FT 3 (0.7 m3) SECTION 6 – FILLING 23/55 FT3 (0.7/1.6 m3) NITROGEN CARTRIDGES SECTION 7 – LEAK TESTING AND PAINTING SECTION 8 – OUT-OF-SPEC CARTRIDGES
SECTION 3 – EQUIPMENT 4-15-11 Page 3-1 REV. 2
EQUIPMENT Cartridge Refilling Equipment Part No. ____ 2590
Description _________ CO2 CARTRIDGE RECHARGE UNIT, COMPLETE (Inspection Gauges and CO2 source not included) Consisting of: 2157 Filler Block Assembly (LH) Consisting of: 793 Filler Block, LH Thread 496 Filler Block Stand 257 Cap Screw 3/8 in. (2) 1459 Packaging 2481 Packing Follower 2480 Packing Nut 4346 Handwheel, Machined 906 Lockwasher (2) 560 Spline Shaft 1870 Washer (2) 904 Nut (2) 173 Bolt (2) 174 Nipple 1 in. x 2 in. (3) 175 Tee 1/4 in. NPT (2) 2482 Gas Control Valve (2) 2492 Copper Tubing & Fitting Consisting of: 2485 Union 2486 Nut, Union 2487 Tubing, Copper 24 in. 2488 Square 2489 Tailpiece 2490 Nut 2491 Washer 2591 Cartridge (Spline) Wrench Consisting of: 148 Handle 490 Spline 2658 1/4 in. x 1-1/4 in. Rod Stock (Pin) 4476 Cartridge Vise Assembly (Maximum of 2 in. (5.1 cm) Diameter) Consisting of: 545 Nut (2) 968 Lockwasher (2) 4478 Base 4479 Screw (2) 4480 Handle Assembly 4483 Lead Screw 4487 Handle, Finished 4488 Jaw (2) 4489 Spacer (2) 4624 Pin Note: Cylinder vises for cartridges larger than 2 in. (5.1 cm) in diameter may be purchased from the following companies: www.getzmfg.com www.galiso.com www.hydro-test.com 6380 Strap Wrench
59371
Filler Block Assembly (RH) (Required to fill right hand cartridges) Consisting of: 55723 Filler Block, RH Thread 53675 Neck Ring Spacer 53676 Neck Ring Spacer All additional components same as Part No. 2157 with the exception of Filler Block Assembly
Cartridge Refilling Equipment (Continued) Part No. Description ____ _________ 438601 23/55 ft3 (0.7/1.6 m3) Cartridge Filler Block Assembly (RH) (Required to fill 23/55 ft 3 (0.7/1.6 m3) cartridges) Consisting of: 55723 Filler Block, RH Thread 53675 Neck Ring Spacer 53676 Neck Ring Spacer This assembly does not include filler block stand. Filler block is attached to cartridge valve while cartridge is secured in cylinder vise. 77250 77251 24654 53803 53819 53821
LH Shipping Cap RH Shipping Cap CO2 Cartridge Seal CO2 Cartridge Seal Nitrogen Cartridge Seal Nitrogen Cartridge Seal
Inspection Gauges 433695 Complete Set of CO2 Cartridge Gauges Consisting of: Cylindrical Plug Gauge, 3/4-16 N2 No Go Dia. 0.6930 Thread Plug, 3/4-16 N2 Go P.D. 0.7094 Thread Plug, 3/4-16 N2 No Go P.D. 0.7139 Thread Ring Gauge, 1-1/16-20 NSLH Go P.D. 1.0285 Thread Ring Gauge, 1-1/16-20 NSLH No Go P.D. 1.0180 Set Plug, 1-1/16 NSLH P.D. 1.0285 Set Plug, 1-1/16 NSLH P.D. 1.0180 433696 Complete Set of Nitrogen Cartridge Gauges Consisting of: Ring Gauges, 1/2-14-L1 NPT Plug Gauge, 1/2-14-L1 NPT Cylinder Plug Gauge, 3/4-20 No Go Dia. 0.7027 Thread Plug, 3/4-20-NEF-2B Go P.D. 0.7175 Thread Plug, 3/4-20-NEF-2B No Go P.D. 0.7221 Thread Ring, 1 1/16-20-NSRH Go P.D. 1.0285 Thread Ring, 1 1/16-20-NSRH No Go P.D. 1.0180 Set Plug, 1 1/16-20-NSRH Go P.D. 1.0285 Set Plug, 1 1/16-20-NSRH No Go P.D. 1.0180 Other Inspection Equipment includes: Micrometer 1 in. to 2 in. Filler block thread gauges: Thread Plug, 1 1/16-20-NSRH Go P.D. 1.0300 Thread Plug, 1 1/16-20-NSRH No Go P.D. 1.0374 Thread Plug, 1 1/16-20-NSLH Go P.D. 1.0300 Thread Plug, 1 1/16-20-NSLH No Go P.D. 1.0374 Cylinder Plug Gauge, 1 1/16-20 No Go P.D. 1.0138 Cartridge Test Tank Drawing 819 in the Reference Section details a typical cartridge test tank (capacity 31 cartridges). Although ANSUL does not manufacture the tank, the enclosed drawing will provide the necessary information (gauge of wall steel, immersion heater, etc.) for making the cartridge test tank locally. Dimensions will vary depending on the diameter and quantity of cartridges being tested. To control rust in the cartridge test tank, add 1 Gal (3.79 L) of Hydrotone (anti-rust) or equal to 50 gallons (189.27 L) of water. This is available (in small cans) at filling stations or at automotive supply dealers. Sodium Nitrite (NaSO2) should be added to the tank to maintain a 0.75% (by vol.) solution. Clear cartridge bubble covers, of a type impervious to heat, are recommended.
SECTION 3 – EQUIPMENT 4-15-11 Page 3-2 REV. 2
Cartridge Weighing Scale An accurate scale graduated in easily read 1/8 ounce (3.54 g) increments is also required. Scale must be capable of handling cartridge weights of up to 10 lb (4.5 kg). Any scale selected must be checked twice per shift with weights for accuracy. The scale should be properly mounted to eliminate vibration from the work bench and to avoid scale damage. To keep the cartridge from rolling while being weighed, mount a cradle to the plate and rebalance the scale. The scale shall be calibrated a minimum of once every six months by a certified company. Carbon Dioxide Supply The carbon dioxide supply shall comply with NFPA-10 requirements and conform to Grade B of Federal Specification BB-C101B – April 15, 1971. Nitrogen Supply The nitrogen supply shall be Type-1, Grade B, Class 1 in accordance with Federal Specification BB-N-411C – January 3, 1973.
SECTION 4 – SAFETY AND MAINTENANCE RECOMMENDATIONS 4-15-11 Page 4-1 REV. 2
SAFETY AND MAINTENANCE RECOMMENDATIONS !
WARNING
Failure to follow the safety instructions set forth below could lead to serious personal injury or property damage. Safety
Maintenance 1. Use Neatsfoot oil on packing in filler block and adjust packing gland nut, as required, to prevent loss of gas. 2. Use gauge cleaner and preservative to prolong the life of gauges. 3. Store gauges and tools carefully to prevent damage, rust and/or corrosion. 4. Replace or repair damaged tools or equipment immediately.
1. A hard hat fitted with a full face shield is required. 2. Use a safety guard at the filling block. 3. When working with filled cartridges, keep bottom end pointed away from operator (and others working in the area) at all times. 4. Never work on a cartridge (or any pressure vessel) with your head or body positioned over, or in line with, the normal thrust of the cartridge should the seal disc rupture (or should a valve or fill cap fail). 5. Keep the cover on the cartridge test tank closed, except while inserting, inspecting or removing cartridges. 6. Plastic cartridge bubble covers must be of the heat resistant type. 7. Safety shipping caps must be in place on charged cartridges before storing or shipping. 8. Never remove the safety shipping cap from a gas supply cylinder until it has been securely mounted. Local codes will also dictate safe methods for storage of spare cylinders; chaining them to a wall will normally be satisfactory. 9. Each cartridge must be weighed immediately after filling to assure that it has not been overfilled. If the cartridge has been overfilled, as it warms up in the bath, the internal pressure will rise and could cause the cartridge seal disc to rupture. Since the cartridge lacks a safety shipping cap at this stage, the cartridge could become a projectile. 10. Cartridges should always be stored with the bottom of the cartridge pointed away from the operator or other personnel. 11. Wear gloves when handling cold cartridges. NOTICE These are but the most obvious precautions and they must be supplemented by your own safety procedures as well as strict observance of all state, local and federal safety codes and standards.
5. Inspection gauges and filler block shall be calibrated and checked regularly.* In addition, should a ring gauge be dropped, it must be recalibrated with the proper set plug before using. * This service can be provided by ANSUL Marinette for a nominal charge, but a purchase order must accompany the material. Direct all correspondence to the attention of the Quality Control Department. (For ease of shipment, return filler block without mounting stand and handwheel.)
SECTION 5 – PRE-FILLING INSPECTION PROCEDURES 4-15-11 Page 5-1 REV. 2
PRE-FILLING INSPECTION PROCEDURES
Using Cartridge Gauges
Purpose
If the threads on the inside and outside of the cartridge are within specifications and are not damaged in any way, the gauges will work with ease as specified in the following paragraphs. At no time should the gauges be forced on the cartridges. If this is done, the life of the gauges will be shortened considerably and cartridges will be checked with gauges that are not within specifications.
The proper inspection of cartridges before filling is mandatory; not only to ensure the integrity of the filled cartridge assembly, but also to avoid possible personal injury to persons filling or using a worn or damaged cartridge. For example, the external cartridge thread is not as strong as the filling block or the cartridge receiver insert. If the threads become undersized, for whatever reason, the cartridge may break loose from the assembly it is mated with due to the high end thrust caused by gas pressure. Likewise, the shear strength of the seal assembly is directly dependent on the internal cartridge threads staying within specification. Consider that there may be ANSUL cartridges in service which are over fifty years old. While age alone does not determine the fitness of cartridges, it is a factor, along with usage and exposure to corrosive atmospheres. The seat machined in the cartridge and the external gasket surface must also be clean and free of nicks. Remove any foreign material such as dirt or dry chemical which may have accumulated in the cartridge. Cartridges which have been burned or damaged must be scrapped. General Inspection 1. Non-ANSUL cartridges shall not be refilled using these procedures. The manufacturer of those cartridges should be consulted for their own procedures and recommendations. 2. Before filling, ensure cartridge complies with the appropriate NFPA and DOT hydrostatic test requirements. 3. Make certain cartridge is empty. If cartridge is charged or partially charged, place cartridge in cartridge receiver of bleed off assembly and bleed off pressure. 4. Fire burned, damaged, badly corroded or pitted cartridges must not be refilled. Refer to CGA pamphlet C-6 for additional recommendations. 5. Cartridges with damaged threads must not be refilled. If available, use a thread chaser to repair external threads and tap to repair internal threads. After repair, check threads with gauges as detailed on Pages 3-1 and 3-2. If cartridge cannot be repaired properly, it must be discarded. 6. ICC or DOT stamping must be legible. If not, the cartridge shall be discarded. (Wire brush if necessary.) (Cartridges 1 1/2 in. (38.1 mm) diameter or less are not stamped.) 7. Stamped weight of cartridge must be legible. Wire brush if necessary. If stamped weight can not be determined, cartridge must be discarded. 8. Remove seal assembly and check internal threads and seal seat for damage. Reject cartridge and properly discard if damaged. 9. Remove any dry chemical or foreign material from inside of cartridge. Blow cartridge out with air jet. 10. Prepare cartridge for subsequent painting. Remove rust, dirt, scale, etc. 11. Inspect cartridge threads for indication of wear or damage. If in doubt, use appropriate thread gauges.
Cartridge gauges must never be used as thread chasers. Wire brush dirty or rusty cartridge threads before checking with gauge. A thin dressing of light machine oil will extend the life of a gauge. All gauges shall be calibrated a minimum of once per year. 1. Cylindrical plug gauge 3/4-16N-1, No Go 0.6930. This gauge is used for checking the minor diameter of the internal threads in the cartridge and is marked: “Cart. Wear No Go Minor D 0.6930 in.” This gauge should not enter into the threaded hole more than 1/8 in. (3.2 mm). If this gauge enters the cartridge more than 1/8 in. (3.2 mm), the cartridge is not to be used and must be condemned and discarded. The reason for this is that if the minor diameter is too large, a seal could relieve when the cartridge is being filled or tested in the water bath. 2. Double end thread plug gauge 3/4-16-N-1 marked: “Go P.D. 0.7094 in.” on one end and “No Go P.D. 0.7139 in.” on the other end. The “Go” thread plug member is applied to the cartridge by threading it into the 3/4 in. threaded hole and should turn in all the way until the end strikes against the seat of the cartridge. If the “Go” member does not enter all the way into the seat of the cartridge, the hole must be tapped out with the correct size tap which can be furnished by ANSUL. (After tapping the threads, the cartridge must be checked again with both gauges as specified, and any metal filings from retapping should be cleared out of cartridge interior.) The “No Go” thread plug member is applied to the cartridge in the same manner as the “Go” member. However, this “No Go” member must not turn into the cartridge more than 1 1/2 turns. If the “No Go” member enters the cartridge more than 1 1/2 turns, the cartridge must be condemned and discarded. The application of the minor diameter gauge (cylindrical plug) must not be confused with that of the thread plug gauge. The minor diameter gauge checks only the minor diameter of the 3/4 in. threads; the thread plug gauge checks the pitch diameter of the 3/4 in. threads. For example, a cartridge may be a reject in the application of the minor diameter gauge and be acceptable in application of the thread gauge or vice versa. In either case, the cartridge should not be used.
SECTION 5 – PRE-FILLING INSPECTION PROCEDURES 4-15-11 Page 5-2 REV. 2
PRE-FILLING INSPECTION PROCEDURES (Continued) Using Cartridge Gauges (Continued) 3. Thread ring gauge 1.0610-20-NS-LEFT HAND “Go” marked: “Cart. Wear Go. P.D. 1.0285 in.” This “Go” thread ring gauge is applied to the cartridge by threading it onto the outside threads of the cartridge. It should go down all the way until the side of the gauge comes in contact with the shoulder below the threads. If the “Go” gauge does not thread all the way down, the threads must be chased with a die which can be furnished by Tyco Fire Protection Products. (After chasing with a die, the threads must again be checked with the thread ring gauges as specified.) 4. Thread ring gauge 1.0610-20-NS LEFT HAND “No Go” marked: ʻʻSpecial Cart. Wear No Go P.D. 1.0180 in.ʼʼ The “No Go” thread ring gauge is to be applied in the same manner as the “Go” thread ring gauge, however, this “No Go” gauge must not turn on the cartridge threads more than 1 1/2 turns. If it goes on more than specified, the cartridge must be condemned and discarded. 5. The major diameter of the external cartridge thread should be checked with a micrometer to 1.0538 minimum.
SECTION 6 – FILLING CARBON DIOXIDE CARTRIDGES 4-15-11 Page 6-1 REV. 2
FILLING CARBON DIOXIDE CARTRIDGES !
WARNING
See safety instructions in Section 2 before proceeding. To lessen the risk of personal injury or property damage, follow all instructions in the proper sequence. Equipment Setup 1. Attach filling unit to bench and connect to either the gravity flow or siphon tube type supply of carbon dioxide (CO2). (See Figures 1 and 2.) The 50 lb (22.7 kg) CO 2 gravity flow cylinder should be inclined at an angle of about 45 degrees. It must also be fastened securely in this position. The siphon tube type of CO2 cylinder would be more convenient, if available. This type of cylinder should be fastened securely to the bench or wall in an upright position. 2. Attach cartridge vise to bench near filling unit. 3. A scale of balance or digital type construction (properly mounted) with 1/8 ounce (3.54 g) graduations and capable of 10 lb (4.5 kg) capacity, shall be used.
GAS CONTROL VALVE
GRAVITY FLOW CYLINDER
GAS RELEASE VALVE
45°
CO2 CYLINDER VALVE
VENT TO UNOCCUPIED AREA
FIGURE 1 007305
GAS CONTROL VALVE CO2 CYLINDER VALVE
GAS RELEASE VALVE
VENT TO UNOCCUPIED AREA
SIPHON TUBE TYPE CO2 CYLINDER
FIGURE 2 007306
SECTION 6 – FILLING CARBON DIOXIDE CARTRIDGES 4-15-11 Page 6-2
FILLING CARBON DIOXIDE CARTRIDGES (Continued)
5. Before inserting new seal, all cartridges must be inspected as detailed in Section 3.
Cartridge Refill Procedure
6. Thread new seal into the cartridge snugly, but do not tighten.
NOTICE Procedures apply to left-handed CO2 cartridge threads. For right-handed cartridges, simply reverse thread direction instructions. 1. Remove shipping cap. 2. If seal is not punctured, place cartridge in cartridge receiver of bleed off assembly and bleed off pressure. (See Figure 3.) If seal is already punctured, proceed to Step 3. VENT TO UNOCCUPIED AREA
CARTRIDGE BLEED OFF ASSEMBLY
7. Check the weight of the empty cartridge. This is a double check against the possibility of some foreign material being lodged in the cartridge. The check is made by subtracting the minimum fill weight indicated in the Cartridge Specification Table in the Reference Section for the cartridge being filled, from the weight stamped on the cartridge. If weight of cartridge varies more than 1/8 ounce (3.54 g) from stamped weight, recheck for foreign material in cartridge. Reweigh and reject all cartridges which exceed 1/8 ounce (3.54 g) tolerance (actual or stamped weight). 8. It is advisable to pre-cool the cartridges in a freezer before attempting to fill them with CO2. They will fill faster than when they are at room temperature.
CHECK VALVES
9. With completion of the previous steps, proceed to fill the CO2 cartridge by completing the following procedures and referring to Figures 1 and 2:
CARTRIDGE RECEIVERS (RIGHT AND LEFT HAND)
a. Make sure gas release, gas control and CO2 cylinder valves are closed.
SCHEDULE 40 PIPING
FIGURE 3 007307
3. Place and secure cartridge to be recharged in a cartridge/cylinder vise of appropriate size for cartridge to be recharged. Refer to CO2 Cartridge Specification Table located in reference material. (See Figure 4.)
b. Insert the cartridge into the filling unit by inserting the spline shaft down as far as the handle or handwheel will allow it to go, turning the handle clockwise and pushing down at the same time. This will allow the spline end of the shaft to project about 1 in. (25 mm) from the filling unit. Fit the cartridge into the unit by guiding it with one hand, while at the same time turning the handle clockwise with the other hand (left-hand threads on cartridge and filling unit). (See Figure 5.) Take extreme care not to get the threads of the cartridge crossed into the filling unit. Tighten cartridge snugly into place with the aid of the strapwrench. DO NOT FORCE A TIGHT FIT.
4. Remove punctured seal from the cartridge using spline wrench. (See Figure 4.) SPLINE WRENCH
FILLER BLOCK
SPLINE SHAFT
FIGURE 5 CARTRIDGE VISE
007309
c. Back the seal from the cartridge seat by turning the handle counterclockwise one half to one full turn. d. Slowly open CO2 cylinder valve wide open. Open gas control valve at least one full turn for approximately five seconds when filling ANSUL 20 lb cartridges, ten seconds for the ANSUL 30 lb cartridges, and three to five seconds for the 5 lb and 10 lb cartridges. This time will vary depending on the temperature of the cartridges and the 50 lb (22.7 kg) CO2 cylinder.
SHOWN: PART NO. 4476, CARTRIDGE VISE ASSEMBLY, MAX. 2 IN. (5.1 cm) DIAMETER
FIGURE 4 007308
SECTION 6 – FILLING CARBON DIOXIDE CARTRIDGES 4-15-11 Page 6-3
FILLING CARBON DIOXIDE CARTRIDGES (Continued)
11.. 11 !
Cartridge Refill Procedure (Continued) e. When the cartridge is filled with a sufficient sufficient quantity of CO2, thread the seal down into the cartridge by turning the handwheel clockwise until the seal fits snugly on the cartridge seat. (See Figure 6.)
Each cartridge must be weighed immediately after filling to assure that it has not been overfilled. If the cartridge has been overfilled, as it warms up, the internal pressure will rise and could cause the cartridge seal disc to rupture. Lacking a safety shipping cap, the cartridge will ʻʻrocketʼʼ and severe personal injury or property damage could result.
SEAL SEAT
Weigh cartridge immediately after it has been removed from filling unit. It should weigh within ± 1/8 ounce (3.54 g) of its stamped weight. If it weighs less, replace the cartridge in the filling unit and add the necessary amount of CO2 to bring it up to the stamped weight. (It may be necessary to re-cool cartridge to take additional gas.) If the cartridge is overweight, place the cartridge in the vise and retract the seal with the spline wrench just enough to allow the gas to escape slowly and then resnug. Reweigh the cartridge. Repeat this procedure until proper weight has been reached. (Although a tolerance of ± 1/8 ounce (3.54 g) is allowed from the weight stamped on the cartridge, it is good practice to try to hold the weight to the plus tolerance only. only. This is advisable because in the final weighing prior to using, any cartridge which reads under the minus 1/8 ounce (3.54 g) weight may be a possible leaker. If weight loss is below stamped weight, but is not below minus 1/8 ounce (3.54 g), it is possible to retighten the seal and put the cartridge back into the hot water bath for further examination.)
FIGURE 6 007310
f. Clo Close se the the gas gas cont control rol val valve. ve. g. Open the the gas release release valve valve until all gas gas has escaped escaped between the filling unit and control valve. NOTICE Very often when charging the cartridge, there will be leakage around the cartridge threads. Usually this is slight. Donʼt try to tighten the cartridge more than just snug. If a leak should occur around the spline shaft packing nut, tighten packing nut. Each filler block is packed around the spline shaft with a leather lacing treated with Neatsfoot Oil. Periodically, the packing nut should be removed and the spline shaft lubricated with this oil to ease turning of the handle.
12. !
WARNING
Care must be taken not to tighten the seal excessively. Otherwise the seal will break or the threads will strip. Replace the cartridge in the vise and tighten the seal firmly in place. A tightening torque of 40 to 50 ft lb (54.2 to 67.8 Nm) is required for optimum sealing.
10. !
WARNING
WARNING
Since the cartridge lacks a safety shipping cap at this time, the cartridge could become a projectile. Remove cartridge from filling unit by first loosening the cartridge with a strap wrench by turning counterclockwise approximately 1/8 of a turn and then backing it out completely by turning the handwheel counterclockwise. (See Figure 7.) Always keep one hand on the cartridge while backing it out so that it does not fall.
13. Immediately ensure filled cartridges have have safety shipping shipping caps installed. (See Figure 8.) All refilled cartridges shall utilize only the following safety shipping caps: the left-hand threaded safety shipping caps are Part No. 77250 while the right-hand threaded safety shipping caps are Part No. 77251. If an older style shipping cap is found, it should be replaced with the appropriate shipping cap described above.
SAFETY SHIPPING CAP
FIGURE 7 007311
FIGURE 8 007312
SECTION 6 – FILLING CARBON DIOXIDE CARTRIDGES 4-15-11 Page 6-4
FILLING CARBON DIOXIDE CARTRIDGES (Continued) Cartridge Refill Procedure (Continued) 14. When the CO2 supply cylinder becomes nearly empty, it will become quite difficult to charge the cartridge regardless of how cold it may be. Even though there will be a high gas pressure, a cylinder is considered empty when all the liquid CO2 has been used. One way to determine that a cylinder is empty is to check for an absence of ʻʻsnowʼʼ when the valve is opened. To get a better picture of this, as soon as a new cylinder is hooked up, open the cylinder valve and the gas control valve allowing a small amount of gas to escape through the filling unit (minus cartridge) into space. You will notice snowflakes form about 4–12 in. (10–30 cm) away from filling unit. When the 50 lb ( 22.7 kg) cylinder is empty, try the same thing. You will notice gas escaping, but no snow. Another way of checking a CO2 cylinder is to weigh it before and after use. The filled weight is stamped on each cylinder. NOTICE If any cartridge continues to leak after filling instructions mentioned in this procedure are correctly followed, the empty cartridge should be taken out of service and destroyed.
SECTION 7 – FILLING NITROGEN CARTRIDGES SMALLER THAN 23 FT 3 (0.7 m3) 4-15-11 Page 7-1 REV. 2 FILLING NITROGEN CARTRIDGES SMALLER THAN 23 FT 3 (0.7 m3) !
CAUTION
See safety instructions in Section 2 before proceeding. To lessen the risk of personal injury or property damage, follow all instructions in the proper sequence.
Equipment Setup 1. Attach filling unit to bench and connect nitrogen supply. (See Figure 9.) If using cylinders, they must be fastened securely to the bench or wall. 2. Attach cartridge vise to bench near filling unit. 3. A scale of balance or digital type construction (properly mounted) with 1/8 ounce (3.54 g) graduations capable of 10 lb (4.5 kg) capacity, shall be used. GAS CONTROL VALVE
NITROGEN CYLINDER VALVE
NITROGEN CYLINDER
GAS RELEASE VALVE
VENT TO UNOCCUPIED AREA
FIGURE 9 007313
SECTION 7 – FILLING NITROGEN CARTRIDGES SMALLER THAN 23 FT 3 (0.7 m3) 4-15-11 Page 7-2
FILLING NITROGEN CARTRIDGES SMALLER THAN 23 FT 3 (0.7 m3) (Continued)
5. Before inserting new seal, all cartridges must be inspected as detailed in Section 3.
Cartridge Refill Procedure
6. Thread new seal into the cartridge snugly, but do not tighten.
1. Remove shipping cap.
7. Check the weight of the empty cartridge. This is a double check against the possibility of some foreign material being lodged in the cartridge. The check is made by subtracting the minimum fill weight indicated in the Cartridge Specification Table in Reference Section for the cartridge being filled from the weight stamped on the cartridge. If weight of cartridge varies more than 1/8 ounce (3.54 g) from stamped weight, recheck for foreign material in cartridge. Reweigh and reject all cartridges which exceed 1/8 ounce (3.54 g) tolerance (actual or stamped weight).
2. If seal is not punctured, place cartridge in cartridge receiver of bleed off assembly and bleed off pressure. (See Figure 10.) If seal is already punctured, proceed to Step 3. VENT TO UNOCCUPIED AREA
CARTRIDGE BLEED OFF ASSEMBLY
CHECK VALVES
8. In order for the cartridge to readily accept the nitrogen charge required, it is recommended that the cartridge be placed in a freezer and cooled to approximately 0 °F (–18 °C). This will allow the cartridge to be filled faster and will result in fewer underfilled cartridges.
CARTRIDGE RECEIVERS (RIGHT AND LEFT HAND)
SCHEDULE 40 PIPING
9. With completion of the previous steps, proceed to fill the nitrogen cartridge by completing the following procedures and refer to Figure 9: a. Make sure gas control, gas release and nitrogen cylinder valves are closed.
FIGURE 10 007314
3. Place and secure cartridge to be recharged in a cartridge/cylinder vise of appropriate size for cartridge to be recharged. Refer to Nitrogen Cartridge Specification Table located in reference material. (See Figure 11.)
b. If neck ring spacers are needed, choose the appropriate size as shown in Figure 12. Place the spacer over the cartridge threads and let it rest on the cartridge shoulder. NECK LENGTH _____________ LESS THAN 1/8 IN. (3.2 mm) APPROX. 1/4 IN. (6.4 mm) GREATER THAN 1/4 IN. (6.4 mm)
SPACER SIZE ____________ NO SPACER REQUIRED 1/8 IN. (3.2 mm) 1/4 IN. (6.4 mm)
4. Remove punctured seal from the cartridge using spline wrench. (See Figure 11.) NECK LENGTH (SEE TABLE)
SPLINE WRENCH
CARTRIDGE VISE
SPACER
SHOWN: PART NO. 4476, CARTRIDGE VISE ASSEMBLY, MAX. 2 IN. (5.1 cm) DIAMETER
FIGURE 11 007315
FIGURE 12 007316
SECTION 7 – FILLING NITROGEN CARTRIDGES SMALLER THAN 23 FT 3 (0.7 m3) 4-15-11 Page 7-3
FILLING NITROGEN CARTRIDGES SMALLER THAN 23 FT 3 (0.7 m3) (Continued)
g. Close the gas control valve. h. Open the gas release valve until all gas has escaped between filling unit and control valve.
Cartridge Refill Procedure (Continued) c. Insert the cartridge into filling unit by inserting the spline shaft down as far as the handwheel will allow it to go, turning the handle clockwise and pushing down at the same time. This will allow the spline end of the shaft to engage the seal body. Thread the cartridge into the unit by guiding it with one hand, while at the same time turning the handle counterclockwise with the other hand (Right-hand threads on cartridge and filling unit). (See Figure 13.)
NOTICE Very often when charging the cartridge, there will be leakage around the cartridge threads. Usually this is slight. Donʼt try to tighten the cartridge more than just snug. If a leak should occur around the spline shaft packing nut, tighten packing nut. Each filler block is packed around the spline shaft with a leather lacing which is treated with Neatsfoot Oil. Periodically, the packing nut should be removed and the spline shaft lubricated with this oil to ease turning of the handle.
Take extreme care not to get the threads of the cartridge crossed in the filling unit. Tighten cartridge snugly into the place with the aid of a strap wrench. DO NOT FORCE A TIGHT FIT. 10.
! FILLER BLOCK
CAUTION
Since the cartridge lacks a safety shipping cap at this time, the cartridge could become a projectile.
SPLINE SHAFT
Remove cartridge from filling unit by first loosening the cartridge with a strapwrench, turning clockwise approximately 1/8 of a turn and then backing it out completely by turning the handwheel clockwise. Always keep one hand on the cartridge while backing it out so that it does not fall. (See Figure 15.)
FIGURE 13 007317
d. Back the seal from the cartridge seat by turning the handle counterclockwise one-half to one full turn. e. Slowly open nitrogen cylinder valve wide open. Note pressure on gauge. Open gas control valve. A noticeable drop in pressure will be indicated when gas control valve is opened. The gauge will almost immediately (3-5 seconds) return to a steady pressure reading. The equalization of pressure between gauge and cartridge means the cartridge is filled. The time will vary due to the temperature of cartridges and nitrogen cylinder. f. When the cartridge is filled with a sufficient quantity of nitrogen, thread the seal down into the cartridge by turning the handle clockwise until the seal fits snugly on the cartridge seat. (See Figure 14.)
SEAL SEAT
FIGURE 14 007318
FIGURE 15 007319
SECTION 7 – FILLING NITROGEN CARTRIDGES SMALLER THAN 23 FT 3 (0.7 m3) 4-15-11 Page 7-4
FILLING NITROGEN CARTRIDGES SMALLER THAN 23 FT 3 (0.7 m3) (Continued) Cartridge Refill Procedure (Continued) 11. !
WARNING
Each cartridge must be weighed immediately after filling to assure that it has not been overfilled. If the cartridge has been overfilled, as it warms up, the internal pressure will rise and could cause the cartridge seal disc to rupture. Lacking a safety shipping cap, the cartridge will ʻʻrocketʼʼ and severe personal injury or property damage could result. Weigh cartridge immediately after it has been removed from filling unit. It should weigh within ± 1/8 ounce (3.54 g) of its stamped weight. If it weighs less, replace the cartridge in the filling unit and add the necessary amount of N 2 to bring it up to the stamped weight. (It may be necessary to re-cool cartridge to take additional gas.) If the cartridge is overweight, place the cartridge in the vise and retract the seal with the spline wrench just enough to allow the gas to escape slowly and then resnug. Reweigh the cartridge. Repeat this procedure until proper weight has been reached. (Although we allow a tolerance of ± 1/8 ounce (3.54 g) from the weight stamped on the cartridge, it is good practice to try to hold the weight to the plus tolerance only. This is advisable because in the final weighing prior to using, any cartridge which reads under the minus 1/8 ounce (3.54 g) weight may be a possible leaker. If weight loss is below stamped weight, but is not below minus 1/8 ounce (3.54 g), it is possible to retighten the seal and put the cartridge back into the hot water bath for further examination.) 12. !
WARNING
Care must be taken not to tighten the seal excessively. Otherwise the seal will break or the threads will strip. Replace the cartridge in the vise and tighten the seal firmly in place. A tightening torque of 40 to 50 ft lb (54.2 to 67.8 Nm) is required for optimum sealing. 13. Immediately ensure filled cartridges have safety shipping caps installed. (See Figure 8.) All refilled cartridges shall utilize only the following safety shipping caps: the left-hand threaded safety shipping caps are Part No. 77250 while the right-hand threaded safety shipping caps are Part No. 77251. If an older style shipping cap is found, it should be replaced with the appropriate shipping cap described above. NOTICE If any cartridge continues to leak after filling instructions mentioned in this procedure are correctly followed, the empty cartridge should be taken out of service and destroyed.
Nitrogen Supply Cylinder The number of cartridges that can be charged from a nitrogen supply cylinder depends on methods used, if the cartridges are being cooled, how warm the cylinder is, and the amount of leakage from the filling unit. For example, approximately 25 LT-20 cartridges can be filled from a 400 ft3 (11.3 m3) cylinder. When the supply cylinder pressure drops below 1800 psi (124.1 bar), it will become quite difficult to charge the cartridge regardless of its temperature. The nitrogen supply can be determined by the pressure reading indicated on the cylinder valve gauge or by weighing the cylinder before and after use. Immediately ensure filled cartridges have safety shipping caps installed. Proceed to Section 7, Leak Testing and Painting.
SECTION 8 – FILLING 23/55 FT3 (0.7/1.6 m3) NITROGEN CARTRIDGES 4-15-11 Page 8-1 REV. 2 FILLING 23/55 FT3 (0.7/1.6 m3) NITROGEN CARTRIDGES !
Booster Pump Specifications Note: Pump not supplied by ANSUL. Other manufacturerʼs pumps may be used as long as the following technical specifications are met.
CAUTION
See safety instructions in Section 2 before proceeding. To lessen the risk of personal injury or property damage, follow all instructions in the proper sequence. Equipment Setup 1. Place and secure cartridge to be recharged in a cylinder vise capable of handling cylinders up to a diameter of 7 in. (17.8 cm). Cartridge must be inserted into vise in the vertical position. (See Figure 16.) Note: Cylinder vises for cartridges larger than 2 in. (5.1 cm) in diameter may be purchased from the following companies: www.getzmfg.com www.galiso.com www.hydro-test.com
Sprague Air-Operated Gas Booster – Model No.: S-86-JN-15 Ref. No: 90081-1 Ratio: 15:1 Driving Air Supply (See Note): 25-200 psi (1.7-13.8 bar) Precharge Inlet Air Range: 100-3100 psi (7.0-213.7 bar) Outlet Air Range: 375-3100 psi (25.9-213.7 bar) Port Thread Size: Driving Air – 1/2 NPT Inlet-Outlet Air – 1/4 NPT Size: Length – 17.5 in. (44.5 cm) Width – 7.75 in. (19.7 cm) Weight: Actual – 18 lb (8.2 kg) Shipping – 21 lb (9.5 kg) Note: Maximum driving air consumption of the boosters is approximately 80 SCFM at 100 psi (7.0 bar). Boosters will operate with less than 80 SCFM and with less than 100 psi (7.0 bar). Cartridge Refill Procedure 1. Remove shipping cap, and gauge guard from cartridge. 2. If seal is not punctured, place cartridge in cylinder vise capable of handling cylinders up to 7 in. (17.8 cm) in diameter. 3. Insert spline wrench and slowly loosen seal until gas audibly begins to vent. Allow all pressure to vent until gauge indicates zero and gas is completely vented. If seal is punctured, proceed to Step 4. This may take up to 30 minutes. !
CAUTION
Do not attempt to remove seal completely while gas is venting. Failure to observe this precaution may result in personal injury.
FIGURE 16 008685
4. Remove punctured seal from the cartridge using spline wrench. (See Figure 17.)
2. Due to fill volumes (approximately 23 ft3 and 55 ft3 (0.7 m3 and 1.6 m3) and fill pressures of 2015 psi (138.9 bar) at 70 °F (21 °C), a nitrogen booster pump is recommended.
SPLINE WRENCH
REMOVE GAUGE GUARD
SECURE IN CYLINDER VISE
FIGURE 17 008679
5. Before inserting new seal, all cartridges must be inspected as detailed in Section 3. 6. Thread new seal into the cartridge snugly, but do not tighten.
SECTION 8 – FILLING 23/55 FT3 (0.7/1.6 m3) NITROGEN CARTRIDGES 4-15-11 Page 8-2
FILLING 23/55 FT3 (0.7/1.6 m3) NITROGEN CARTRIDGES (Continued)
e. Attach the hose from the booster pump to the filler block inlet.
Cartridge Refill Procedure (Continued) 7. In order for the cartridge to readily accept the nitrogen charge required, it is recommended that the cartridge be placed in a freezer and cooled to approximately 0 °F (–18 °C). This will allow the cartridge to be filled faster and will result in fewer underfilled cartridges.
GAS CONTROL VALVE
8. With completion of the previous steps, proceed to fill the nitrogen cartridge by completing the following procedures:
FILLER BLOCK
a. Make sure gas control, gas release and nitrogen pump valves are closed. b. If neck ring spacers are needed, choose the appropriate size as shown in Figure 18. Place the spacer over the cartridge threads and let it rest on the cartridge shoulder. NECK LENGTH _____________ LESS THAN 1/8 IN. (3 mm) APPROX. 1/4 IN. (6 mm) GREATER THAN 1/4 IN. (6 mm)
GAS RELEASE VALVE
SPACER SIZE ____________ NO SPACER REQUIRED 1/8 IN. (3 mm) 1/4 IN. (6 mm)
VENT TO UNOCCUPIED AREA
FIGURE 19
NECK LENGTH (SEE TABLE)
008680
f. Back the seal from the cartridge seat by turning the handle counterclockwise one-half to one full turn. g. Follow booster pump manufacturerʼs documentation for hookup and filling procedures. h. When the cartridge is filled with a sufficient quantity of nitrogen, thread the seal down into the cartridge by turning the handle clockwise until the seal fits snugly on the cartridge seat. (See Figure 20.) SPACER SEAL SEAT
FIGURE 20 007318
i. FIGURE 18
!
007316
Care must be taken not to tighten the seal excessively. Otherwise the seal will break or the threads will strip.
c. Thread the filler block onto the valve, approximately two threads down, ensuring that the spline wrench is seated inside the cartridge seal. Hand tighten.
Replace the cartridge in the vise and tighten the seal firmly in place. A tightening torque of 45 ft lb (61.0 Nm) is required for optimum sealing.
Note: Take extreme caution not to cross the threads of the filler block. d. Make sure vent valve on filler block is closed.
WARNING
j.
Close the gas control valve.
SECTION 8 – FILLING 23/55 FT3 (0.7/1.6 m3) NITROGEN CARTRIDGES 4-15-11 Page 8-3
FILLING 23/55 FT3 (0.7/1.6 m3) NITROGEN CARTRIDGES (Continued) Cartridge Refill Procedure (Continued) k. Open the gas release valve until all gas escapes between filling unit and control valve. NOTICE Very often when charging the cartridge, there will be leakage around the cartridge threads. Usually this is slight. Donʼt try to tighten the cartridge more than just snug. If a leak should occur around the spline shaft packing nut, tighten packing nut. Each filler block is packed around the spline shaft with a leather lacing which is treated with Neatsfoot Oil. Periodically, the packing nut should be removed and the spline shaft lubricated with this oil to ease turning of the handle. 9. !
CAUTION
Since the cartridge lacks a safety shipping cap at this time, the cartridge could become a projectile. Remove fill hose from filler block inlet. Remove filler block from cylinder valve. 10. Immediately ensure filled cartridges have gauge guards and safety shipping caps installed. (See Figure 21.) All refilled cartridges shall utilize only the following safety shipping caps: the threaded Cartridge Safety Shipping Cap (Left-hand, Part No. 77250; Right-hand, Part No. 77251) and the Cylinder Shipping Cap (Part No. 73066). If an older style shipping cap is found, it should be replaced with the appropriate shipping cap described above. NOTICE If any cartridge continues to leak after filling instructions mentioned in this procedure are correctly followed, the empty cartridge should be taken out of service and destroyed.
FIGURE 21 008683
SECTION 9 – LEAK TESTING AND PAINTING 4-15-11 Page 9-1
LEAK TESTING AND PAINTING !
WARNING
Never work in a position above cartridges placed in the test bath. If a cartridge seal ruptures due to overfilling, it is usually during the initial warm up period. If seal ruptures, cartridge could become a projectile and cause serious personal injury or damage. Leak Testing 1. The cartridge should be placed in a hot water bath for a period of at least four hours under bubble covers. Note: When leak testing 23/55 ft3 (0.7/1.6 m3) cartridges, make sure that the hot water bath can accommodate a height of 28 in. (71.1 cm) for the 23 ft3 (0.7 m3) cartridge, and 27.9 in. (70.8 cm) for the 55 ft3 (1.6 m3) cartridge. Make sure that the water temperature never drops below 110 °F (43 °C) or goes over 120 °F (49 °C). If the seal has not been tightened enough, bubbles will form immediately and will rise to the surface. If this happens, remove the cartridge from the bath, tighten the seal and re-weigh cartridge to ensure proper weight. Replace cartridge in water bath. After cartridge has warmed up, cover cartridge with bubble cover for the leak test. Submerge bubble cover in water. Do this in such a manner as to allow the air bubbles to escape from the cover. After the bubble cover has been filled with water, and while still submerged, invert it. Check the bottom of the bubble cover for air bubbles. If there are no air bubbles visible, raise bubble cover up and place it over the cartridge, always keeping the bubble cover full of water as it is being moved into position. When the bubble cover is over the cartridge, again check to make sure that there are no bubbles in the cover. If a bubble does show up, remove the bubble cover and repeat procedure. If the bubble appears in the bubble cover a second time, remove cartridge, tighten seal and repeat procedure. If a bubble appears again, release the gas from the cartridge and check the condition of the cartridge seat. If the seat is in satisfactory condition, insert a new seal and recharge the cartridge. 2. Clean and dry the tested cartridges that did not show bubbles after the four hour leakage test. Only cartridges with NO bubbles have passed the test. If small bubbles appeared during the four hour leak test, it does not necessarily indicate CO2 or N 2 leakage. Along with air becoming trapped around the cartridge seal and threads, the hot water can be contaminated by the following: a. Free air dissolved in the water driven out by heat. b. Hydrolysis of water into hydrogen and oxygen. c. Gas created by corrosion. 3. If any small bubbles are found, the cartridge must be retested.
Painting Cartridges Smaller Than 23 ft3 (0.7 m3) Paint the cartridges with a good quality nongloss paint 1.5 – 2.0 mils thick. Color is CCA-GE BEIGE CAMEL. Do not paint external threads. (Stamped information on cartridge must be legible after painting.) Hang the cartridges up to dry using the cartridge caps. Insert wire under cap or into the gas escape holes and bend in the form of a hook. When the paint has dried, apply a thin coating of liquid wax to the external threads. This will help guard against rusting. Painting 23/55 ft3 (0.7/1.6 m3) Cartridges Paint the cartridges using a primer coat of epoxy primer (Part No. 21944), dry film thickness of a minimum of 1.0 mil. Let cartridges dry for 30 minutes at 200 °F (93 °C). After drying, top the primer coat with epoxy polyester (Part No. 21917), dry film thickness of a minimum of 2.0 mils. Dry for 30 minutes at 225 °F (107 °C). Stamped information on cartridge must be legible after painting. Note: If a cartridge needs to be re-painted, this should be done prior to refilling. Final Inspection and Marking Before shipping, recheck weight of cartridge. If cartridge weighs to stamped weight, identify cartridge size by marking on side with ANSUL ink stamp. Stamp artwork can be obtained by contacting the ANSUL Marketing Communications Department. If weight of cartridge is below weight allowed by filling tolerance, the cartridge must be refilled. The weight stamped on a cartridge DOES NOT include shipping cap. Federal regulations prohibit shipment of charged cartridges without a safety shipping cap.
SECTION 10 – OUT-OF-SPEC CARTRIDGES 4-15-11 Page 10-1
OUT-OF-SPEC CARTRIDGES !
WARNING
Be sure cartridges are empty before destroying. Problem _______
Corrective-Action ______________
Small 1-1/16 in. threads
Condemn and discard per CGA P-2 recommendation.
Large 1-1/16 in. threads
Repair with thread chase or condemn and discard per CGA P-2 recommendation.
Large 3/4 in. threads
Condemn and discard per CGA P-2 recommendation.
Small 3/4 in. threads
Repair with tap or condemn and discard per CGA P-2 recommendation.
Bad seat for cartridge seal
Condemn and discard per CGA P-2 recommendation.
Corrosion
Condemn and discard per CGA P-2 recommendation.
Loose hex nut
Condemn and discard per CGA P-2 recommendation.
Short threads (less than 4 full threads)
Condemn and discard per CGA P-2 recommendation.
Large minor diameter on 3/4 in. threads
Condemn and discard per CGA P-2 recommendation.
Fire burned cartridges
Condemn and discard per CGA P-2 recommendation.
SECTION 11 – APPENDIX 4-15-11 Page 11-1
P M A T S
5 4 4 4
4 3 6 3
4 5 0 1
4 5 0 1
5 5 0 1
5 5 0 1
4 2 3 5 1
1 7 7 5 2
6 5 3 7 1
1 0 6 5 1
4 2 9 5 1
1 5 0 5 1
) N m c O I ( S N B E M . I N D I
) 9 . 9 (
) 1 . 5 1 (
) 3 . 7 1 (
) 3 . 7 1 (
) 9 . 4 2 (
) 9 . 4 2 (
) 9 . 2 2 (
) 9 . 2 2 (
) 0 . 0 2 (
) 5 . 9 2 (
) 8 . 8 1 (
) 4 . 6 2 (
2 3 / 9 2 3
6 1 / 5 1 5
6 1 / 3 1 6
6 1 / 3 1 6
6 1 / 3 1 9
6 1 / 3 1 9
9
9
8 / 7 7
8 / 5 1 1
6 1 / 7 7
6 1 / 7 0 1
) N m c O ( I S N A E M . I N D I
) 8 . 3 (
) 8 . 3 (
) 1 . 5 (
) 1 . 5 (
) 1 . 5 (
) 1 . 5 (
) 1 . 5 (
) 1 . 5 (
) 4 . 6 (
) 4 . 6 (
) 1 . 5 (
) 1 . 5 (
2 / 1 1
2 / 1 1
2 / 1 2
2
2
. . T . C E O . P D S
E ) g G ( R A H C F O T H G I E . W Z O
T N A L L E P X E 2 O C – E L B A T N O I T A C I F I C E P S E G D I R T R A C
2
2
2
2
2
2
2 / 1 2
0 0 8 1 E 3
0 0 8 1 E 3
0 0 8 1 E 3
0 0 8 1 E 3
0 0 8 1 E 3
0 0 1 2 A 3
0 0 1 2 A 3
0 0 8 1 E 3
0 0 8 1 E 3
) 2 . 6 5 1 – 2 4 1 (
) 4 . 1 4 2 – 2 . 7 2 2 (
) 4 . 1 4 2 – 2 . 7 2 2 (
) 5 . 9 0 2 – 8 . 8 9 1 (
) 8 . 9 5 1 – 1 . 9 4 1 (
) 1 . 1 9 2 – 4 8 2 (
) 5 . 1 6 4 – 3 . 7 4 4 (
) 2 . 6 5 1 – 2 4 1 (
) 4 . 1 4 2 – 2 . 7 2 2 (
4 / 1 0 1 – 0 1
4 / 1 6 1 – 4 / 3 5 1
2 / 1 5 — 5
2 / 1 8 – 8
—
—
0 0 8 1 E 3
) 5 . 2 4 – 5 . 5 3 (
) 1 . 6 7 – 2 . 9 6 (
) 2 . 6 5 1 – 2 4 1 (
2 / 1 1 – 4 / 1 1
6 1 / 1 1 2 – 6 1 / 7 2
2 / 1 5 – 5
2 / 1 5 – 5
2 / 1 8 – 8
2 / 1 8 – 8
8 / 3 7 – 7
8 / 5 5 – 4 / 1 5
O F ° 2 H 0 . . 7 L S O M V G
7 6 o t 3 6
3 1 1 o t 9 0 1
5 4 2 o t 0 3 2
5 4 2 o t 0 3 2
0 7 3 o t 5 5 3
0 7 3 o t 5 5 3
8 2 3 o t 8 0 3
8 2 3 o t 8 0 3
3 4 4 o t 7 2 4
0 0 7 o t 2 8 6
5 4 2 o t 0 3 2
5 9 3 o t 5 5 3
D . A E D . R I H T
6 1 4 / 3
6 1 4 / 3
6 1 4 / 3
6 1 4 / 3
6 1 4 / 3
6 1 4 / 3
0 2 4 / 3
0 2 4 / 3
0 2 4 / 3
0 2 4 / 3
6 1 4 / 3
6 1 4 / 3
D 0 . A 2 D . E 6 1 / O R H 1 T 1
. H . L
. H . L
. H . L
. H . L
. H . L
. H . L
. H . R
. H . R
. H . R
. H . R
. H . L
. H . L
0 3
0 3 Y R A T I L I M
0 1 1 0 1
0 1 1 0 1 K
0 2 1 0 1
0 3 S P / 0 3 1 0 1
0 2 M N
0 3 M N
L E D O M
5 d n a 4
0 1
0 2
0 2 Y R A T I L I M
L L . L Y I S F A S E E S R A
4 5 6 4 2
4 5 6 4 2
4 5 6 4 2
4 5 6 4 2
4 5 6 4 2
4 5 6 4 2
3 0 8 3 5
3 0 8 3 5
3 0 8 3 5
3 0 8 3 5
4 5 6 4 2
4 5 6 4 2
. . P I Y S H S S A
3 2 5 4
6 1 6 4
4 1 6 4
0 6 6 0 3
5 1 6 4
1 6 6 0 3
0 5 8 5 1
0 9 4 7 1
2 9 4 7 1
1 5 8 5 1
0 2 9 5 1
1 4 0 5 1
SECTION 11 – APPENDIX 4-15-11 Page 11-2
P M A T S
7 5 9 6
5 1 9 6
8 0 0 3 1
2 6 1 3 1
2 7 0 7
8 2 0 7
4 9 8 4
8 9 6 6
0 5 2 9 2
2 9 3 7 5
) 2 . 5 1 (
) 2 . 5 1 (
) 3 . 7 1 (
) 3 . 7 1 (
) 0 . 0 2 (
) 0 . 0 2 (
) 5 . 9 2 (
) 5 . 9 2 (
) 1 . 7 3 (
6
6
6 1 / 3 1 6
6 1 / 3 1 6
8 / 7 7
8 / 7 7
8 / 5 1 1
8 / 5 1 1
) N m c O ( I S N A E M . I N D I
) 1 . 5 (
) 1 . 5 (
) 1 . 5 (
) 1 . 5 (
) 4 . 6 (
) 4 . 6 (
) 4 . 6 (
2
2
2
2
2 / 1 2
2 / 1 2
. . T . C E O . P D S
0 0 8 1 E 3
0 0 8 1 E 3
0 0 8 1 E 3
0 0 8 1 E 3
0 0 1 2 A 3
0 0 1 2 A 3
) N m c O I ( S N B E M . I N D I
T N A L L E P X E N E G O R T I N – E L B A T N O I T A C I F I C E P S E G D I R T R A C
—
) 0 . 6 2 (
) 8 . 0 1 (
) 1 . 7 1 (
8 / 5 4 1
4 / 1 0 1
4 / 1 4
4 / 3 6
) 4 . 6 (
) 1 . 9 (
) 6 . 0 1 (
) 2 . 1 7 (
2 / 1 2
2 / 1 2
6 1 / 9 3
6 1 / 3 4
8 2
) 8 . 0 7 ( 8 / 7 7 2
0 0 1 2 A 3
0 0 1 2 A 3
0 0 8 1 A A 3
0 0 1 2 A A 3
5 1 0 2 A A 3
5 1 0 2 A A 3
) 9 . 6 7 2 – 7 . 2 6 2 (
e c n e r t e r a f e r h C d n n o a i t e c v e l r a r v o n C o e r e t g u u a a r g e p e m e e S T
) 1 . 9 3 – 9 . 1 3 (
) 3 . 9 6 – 1 . 2 6 (
) 3 . 9 6 – 1 . 2 6 (
) 5 . 8 0 1 – 7 . 7 9 (
) 5 . 8 0 1 – 7 . 7 9 (
) 5 . 1 6 4 – 3 . 7 4 4 (
8 / 3 1 – 8 / 1 1
8 / 3 1 – 8 / 1 1
6 1 / 7 2 – 6 1 / 3 2
6 1 / 7 2 – 6 1 / 3 2
6 1 / 3 1 3 – 6 1 / 7 3
6 1 / 3 1 3 – 6 1 / 7 3
4 / 1 6 1 – 4 / 3 5 1
4 / 3 9 – 4 / 1 9
e c n e r t e r a f e r h C d n n o a i t e c v e l r a r v o n C o e r e t g u u a a r g e p e m e e S T
0 0 2 o t 9 7 1
5 4 2 o t 0 3 2
5 4 2 o t 0 3 2
3 4 4 o t 7 2 4
3 4 4 o t 7 2 4
0 0 7 o t 2 8 6
0 0 7 o t 2 8 6
5 3 8 1 o t 2 0 8 1
0 9 6 1 – 3 1 5 1
7 4 0 5 2 3 6 4
7 9 8 0 1
6 1 4 / 3
6 1 4 / 3
0 2 4 / 3
6 1 4 / 3
0 2 4 / 3
0 2 4 / 3
0 2 4 / 3
0 2 4 / 3
0 2 4 / 3
0 2 4 / 3
0 2 4 / 3
0 2 4 / 3
. H . L
. H . R
. H . R
. H . L
. H . R
. H . L
. H . R
. H . L
. H . R
. H . R
—
—
E L B U O D 2 0 1 R
5 2 1 1 0 1 A T L
0 5 2 1 0 1 A T L
) 5 . 7 2 – 4 . 0 2 (
) 5 . 7 2 – 4 . 0 2 (
2 3 / 1 3 – 2 3 / 3 2
2 3 / 1 3 – 2 3 / 3 2
O F ° 2 H 0 . . 7 L S O M V G
0 0 2 o t 9 7 1
D . A E D . R I H T D 0 . A 2 D . E 6 1 / O R H 1 T 1
E ) g G ( R A H C F O T H G I E . W Z O
—
) 1 . 9 3 – 9 . 1 3 (
L E D O M
L 5 T L
R 5 T L
R 0 1 T L
L 0 1 T L
R 0 2 T L
L 0 2 T L
R 0 3 T L
L 0 3 T L
0 3 1 0 1 A T L
L L . L Y I S F A S E E S R A
9 1 8 3 5
9 1 8 3 5
3 0 8 3 5
9 1 8 3 5
3 0 8 3 5
3 0 8 3 5
3 0 8 3 5
3 0 8 3 5
1 2 8 3 5
3 0 8 3 5
3 0 8 3 5
3 0 8 3 5
. . P I Y S H S S A
3 1 0 7
9 7 9 6
3 9 1 3 1
7 7 1 3 1
2 3 0 7
2 1 0 7
3 7 3 5
1 4 6 6
7 8 1 9 2
2 2 0 3 7
0 6 0 8 2 4
1 6 0 8 2 4
SECTION 11 – APPENDIX 4-15-11 Page 11-3
TEMPERATURE CORRECTION CHARTS CYLINDER FILL CHART – NITROGEN – 23 FT3 (MEDICAL E) CYLINDER CYLINDER PRESSURE psi
(bar)
2000
(137.9)
1900
(131.0)
1800
(124.1)
1700
(117.2)
1600
(110.3)
1500
(103.4)
1400
(96.5)
1300
(89.6) –65 (–54)
E R U S E S R P L L I F R E D N I L Y C
–40 (–40)
–20 0 20 40 60 80 (–29) (–18) (–7) (4) (16) (27) NITROGEN CYLINDER TEMPERATURE
100 (38)
120 °F (49) (°C)
100 (38)
120 °F (49) (°C)
CYLINDER FILL CHART – NITROGEN – 55 FT3 (MEDICAL E) CYLINDER CYLINDER PRESSURE psi
(bar)
2300
(158.6)
2200
(151.7)
2100
(144.8)
2000
(137.9)
1900
(131.0)
1800
(124.1)
1700
(117.2)
1600
(110.3) –65 (–54)
E R U S E S R P L L I F R E D N I L Y C
–40 (–40)
–20 0 20 40 60 80 (–29) (–18) (–7) (4) (16) (27) NITROGEN CYLINDER TEMPERATURE
SECTION 11 – APPENDIX 4-15-11 Page 11-4
008693
SECTION 11 – APPENDIX 4-15-11 Page 11-5
OUNCES-TO-GRAMS CONVERSION TABLE 1/16 oz = 1.77 grams
13 oz = 368.55 grams
1/8 oz = 3.54 grams
14 oz = 396.89 grams
1/4 oz = 7.09 grams
15 oz = 425.25 grams
5/16 oz = 8.86 grams
16 oz = 453.59 grams
3/8 oz = 10.63 grams
17 oz = 481.95 grams
7/16 oz = 12.40 grams
18 oz = 510.29 grams
1/2 oz = 14.17 grams
19 oz = 538.65 grams
9/16 oz = 15.95 grams
20 oz = 566.99 grams
5/8 oz = 17.72 grams
21 oz = 595.35 grams
3/4 oz = 21.26 grams
22 oz = 623.69 grams
7/8 oz = 24.81 grams
23 oz = 652.05 grams
1 oz = 28.35 grams
24 oz = 680.39 grams
2 oz = 56.70 grams
25 oz = 708.75 grams
3 oz = 85.05 grams
26 oz = 737.09 grams
4 oz = 113.40 grams
27 oz = 765.45 grams
5 oz = 141.75 grams
28 oz = 793.79 grams
6 oz = 170.10 grams
29 oz = 822.15 grams
7 oz = 198.35 grams
30 oz = 850.49 grams
8 oz = 226.80 grams
31 oz = 878.85 grams
9 oz = 255.15 grams
32 oz = 907.18 grams
10 oz = 283.50 grams
33 oz = 935.55 grams
11 oz = 311.85 grams
34 oz = 963.88 grams
12 oz = 340.19 grams
35 oz = 992.25 grams
SECTION 12 – REFERENCES 4-15-11 Page 12-1
REFERENCES 1. ANSUL Technical Bulletin No. 31, Form No. F-80261, ʻʻCarbon Dioxide Cartridgesʼʼ 2. ANSUL Technical Bulletin No. 34, Form No. F-80195, ʻʻUse and Refilling of ANSUL Gas Cartridgesʼʼ 3. ANSUL Technical Bulletin No. 50, Form No. F-81301, ʻʻHydrostatic Retest Requirements for ANSUL Hand Portable and Wheeled Fire Extinguishersʼʼ
Technical Bulletin
ANSUL
®
Number 31 Carbon Dioxide Cartridges For Hand Portable Fire Extinguishers
ANSUL INCORPORATED MARINETTE, WI 54143-2542
Each Ansul hand portable cartridge-operated fire extinguisher is provided with a small cartridge of compressed gas which furnishes the pressure to expel the dry chemical agent. Most of these cartridges are charged with liquid carbon dioxide, but some nitrogen cartridges are used in extreme temperature environments. All Ansul cartridges are manufactured, tested and assembled according to U.S. Department of Transportation regulations. The smaller carbon dioxide cartridges which are exempted from certain D.O.T. regulations (cartridges installed in 4, 5 and 10 lb. extinguishers) are designed, manufactured and tested in accordance with the requirements of Underwriters Laboratories, Inc. Rupture Pressure Every DOT-3E-1800 cylinder is designed to withstand rupture up to a minimum of 6000 psi (41370 kPa) (see chart). One cartridge of every 500 manufactured must be hydrostatically tested to determine rupture pressure. Reports of these tests must be given to the Department of Transportation. Every Ansul cartridge is also subjected to hydrostatic test at 4500 psi (31028 kPa) and pneumatic leakage at 1800 psi (12411 kPa). Because all Ansul cartridges are designed to meet and exceed minimum rupture pressure, a large safety factor between charged pressure (850 psi at 70 °F) (5861 kPa at 21 °C) and minimum rupture pressure (6000 psi) (41370 kPa) is created (see chart). PRESSURE (POUNDS PER SQ. IN.) (850 psi AT 70 °F) (5861 kPa AT 21 °C)
CARTRIDGE CYLINDER RUPTURE PRESSURE (MINIMUM 6000 psi (41370 kPa))
6000 CYLINDER SAFETY MARGIN (MINIMUM 1500 psi (10343 kPa)) 5000 MAXIMUM RUPTURE PRESSURE OF FRANGIBLE DISC (4500 psi (31028 kPa)) 4000
FRANGIBLE DISC RUPTURE RANGE (450 psi (3103 kPa))
MINIMUM RUPTURE PRESSURE OF FRANGIBLE DISC (4050 psi (27925 kPa))
3000
DISC AND CYLINDER SAFETY MARGIN (MINIMUM 3200 psi (22064 kPa))
2000
1000 CHARGED PRESSURE (850 psi AT 70 °F (5861 kPa AT 21 °C))
–50
0
50
100 150 200 TEMPERATURE – °F
250
300
Temperature – Pressure Relationships in Carbon Dioxide Cartridges For 4, 5, 10, 20, and 30 lb. Capacity Ansul Fire Extinguishers 002221
Each cartridge is closed and sealed by a threaded plug containing a frangible disc with carefully controlled material integrity, thickness, and diameter so that it will rupture at pressures between 4050 and 4500 psi (27925 and 31028 kPa) according to D.O.T. requirements. This creates an additional safety factor of at least 1500 psi (10343 kPa) between disc rupture pressure (4050 to 4500 psi) (27925 to 31028 kPa) and minimum cylinder rupture pressure (6000 psi) (41370 kPa) (see chart). Specially designed safety shipping caps should always be utilized on the cartridges whenever they are not installed onto a system or extinguisher. These safety shipping caps protect the threads and seal surfaces while ensuring safe pressure venting of the cartridge should it be exposed to excessive temperatures. Filling and Pressures The weight of carbon dioxide placed in the cartridge is not allowed to exceed 68% of the weight of water the cartridge would hold (68% density). At this density the carbon dioxide is under a pressure of approximately 850 psi at 70 °F (5861 kPa at 21 °C) and about 4200 psi at 200 °F (28959 kPa at 93 °C) (see chart). The cartridge filling process is closely controlled to reduce the possibility of the cartridge being filled over 68% density. Each cartridge is also tested for leakage by immersion in a hot water bath for several hours. This test will detect a leak rate of 1/4 oz. in 127 years. The temperature in the water bath is also high enough to rupture the safety disc in an over-filled cartridge. A final weighing ensures against shipping of overfilled or empty cartridges. Ansulʼs Quality By insisting on the highest manufacturing standards and quality testing procedures, Ansul assures that all its extinguisher cartridges are accurately filled, safe and reliable. Non-Ansul cartridges should never be used in Ansul extinguishers. Refer to Technical Bulletin No. 58, Replacement Components and Service, Form No. F-8922.
ANSUL INCORPORATED, MARINETTE, WI 54143-2542
715-735-7411
Form No. F-80261-1
©1998 Ansul Incorporated
Litho in U.S.A.
Technical Bulletin
ANSUL
®
Number 34
Use And Refilling Of Ansul Gas Cartridges
ANSUL INCORPORATED MARINETTE, WI 54143-2542
Published standards from the National Fire Protection Association, Occupational Health and Safety Act, Underwriters Laboratories and Factory Mutual Laboratories, state that materials other than those furnished by the manufacturer shall not be used in dry chemical extinguishers. This, of course, means that a manufacturerʼs cartridge refilled by anyone not authorized to do so by the manufacturer of the original equipment would not be acceptable. In this bulletin we will discuss certain pitfalls which could occur from not adhering to these standards. 1. Use of non-Ansul cartridges in Ansul extinguishers A. External threads do not fit cartridge receiver 1. Galls threads do not fit cartridge receiver 2. Cartridge strips threads and blows out upon being punctured 3. Does not seat tightly against gasket… a. Impossible to puncture cartridge seal b. After puncturing some gas leaks past threads B. Different design of cartridge seal and its assembly into cartridge body could result in the inability to puncture the cartridge seal when used in an Ansul extinguisher C. These non-Ansul cartridges will not be refilled by Ansul or authorized Ansul agents 2. Refilling of Ansul cartridge by other than authorized agents may result in… A. Threads not checked with “Go” and “No Go” thread gauges with cartridges having dangerously worn threads not being junked B. Damaged threads not being repaired C.
Depth and condition of cartridge seal seat not checked
D. Dangerously rusted or damaged cartridges being refilled E. Cartridges weakened by being involved in a fire being refilled F. Weight of empty cartridge not checked before refilling G. Use of cartridge seal not manufactured by Ansul 1. Disc may rupture as low as 110° F 2. Disc may rupture at temperatures and pressure too high for built-in safety factor 3. May require pipe dope or some other sealing compound to effect temporary sealing of gas. This procedure is not recommended. H. Reuse of Ansul seal body with a new rupture disc not to specification. Used seal body is also more subject to leaking gas. I. Cartridge being underfilled with consequent poor performance J. Cartridge being overfilled 1. A 3/8 ounce overfill in a carbon dioxide filled Model 5 cartridge can cause rupture of seal disc at 130° F (standard filling will result in seal disc rupture at 194° F or more). 2. A 1 ounce overfill in a nitrogen filled Model LT-20-R cartridge can cause rupture at 130° F (standard filling will result in seal disc rupture at 360° F or more). 3. A 4 ounce overfill in a carbon dioxide filled PS-30 cartridge can cause rupture at 115° F (standard filling will result in seal disc rupture at 170° F or more). K. Failure to subject cartridge to 12 hour 115° F water bath test to cull out leakers
L. Poor paint finish because of… 1. Failure to wire brush thoroughly 2. Paint allowed to get on threads 3. Instructions partially obliterated M. Rubber stamped instructions not reproduced after painting N. Threads not treated with proper lubricant to prevent rusting. Rusted external threads make proper seating of cartridge difficult and can cause freezing to threads of cartridge receiver. O. Failure to reweigh before shipping P. May result in failure to rehydrostatic test PS-30, 101-30 and LT-30-R cartridges every five years as required by D.O.T. Ansul Incorporated has had over 40 yearsʼ experience in the manufacture, refilling and testing of gas pressure cartridges for dry chemical extinguishers. The large volume of extinguishers produced by Ansul permits us to manufacture all gas cartridges used in Ansul fire extinguishers. This volume also justifies elaborate equipment for testing every critical feature of Ansul gas cartridges. This is important since the gas pressure cartridge is the heart of a cartridge operated dry chemical fire extinguisher. Over the years rigid standards for refilling Ansul cartridges have been developed. As new inspection procedures have been added, labor saving tools for automation have kept pace allowing us to absorb the costs of the added inspection steps in Ansulʼs cartridge filling department. The tools, fixtures, gauges and other test equipment required to fill and test gas cartridges to the standards of Ansul Incorporated, represent a sizeable capital expenditure. Only the factory and authorized agents for refilling Ansul cartridges realize the volume necessary to justify this expenditure. Cartridge refill volume is also important in keeping material and labor costs at a level so that the extensive quality control in this operation does not become uneconomical. A few Ansul gas cartridges are being refilled by those not authorized to do so. We, like the N.F.P.A. and other agencies, wish to discourage this practice. Those not authorized to fill Ansul cartridges cannot possibly afford to install proper tools, fixtures, gauges and other equipment when their volume of Ansul cartridges refilled totals a few hundred cartridges a year or less. Likewise, when volume is small, certain obvious short cuts in testing procedures must be taken so that the operation shows a profit. In summary, Ansul Incorporated heartily concurs with the N.F.P.A., OSHA and other agencies concerning the fact that spare and refill cartridges other than those furnished by the manufacturer shall not be used in dry chemical fire extinguishers. Again, the gas cartridge is the heart of an Ansul dry chemical fire extinguisher. To assure proper functioning of the extinguisher, the cartridge must be serviced by those qualified to do so.
ANSUL INCORPORATED, MARINETTE, WI 54143-2542
715-735-7411
Form No. F-80195-1
©1998 Ansul Incorporated
Litho in U.S.A.
Technical Bulletin Number 50 Hydrostatic Retest Requirements for ANSUL Portables, Wheeled Units, and Pre-engineered Vessels Federal laws (and in some cases state and municipal statutes) require that most of the pressure vessels associated with ANSUL hand portable and wheeled extinguishers must be periodically hydrostatically retested to ensure their safety. In addition, the laws require hydrostatic retesting of vessels which show evidence of corrosion or mechanical injury. The purpose of this bulletin is to 1) indicate what Tyco Fire Suppression & Building Products understands to be the legal requirements, and 2) provide guidance for the user in determining recommended retest practices and procedures for such vessels. We have prepared a chart, designed to show what we understand to be the current legal requirements for periodic retest, indicating both test intervals and pressures. These requirements are shown for the two principal authorities having jurisdiction over this type of product, the National Fire Protection Association (NFPA); and the Codes of Federal Regulations, (D.O.T., M.S.H.A., and O.S.H.A.). It is important to understand the jurisdiction of these two authorities and how it may effect the product in question. You may wish to refer directly to these principal authorities to make your own interpretation of the current legal requirements. NFPA standards have no force of law in and of themselves unless adopted by a regulatory entity that is empowered by statute to enforce regulations. However, as consensus standards developed by teams of recognized experts, they represent sound fire safety principles, practices and procedures, and we recommend that they be observed in the case of hydrostatic retesting. Moreover, some states and municipalities have adopted NFPA standards as a part of their fire protection codes, including those parts dealing with the maintenance and hydrostatic retesting of extinguishers. OSHA has safety jurisdiction over most workplaces in the U.S., and as such its regulations have the force of federal law. OSHA has not adopted NFPA standards for hydrotesting per se, but its requirements follow NFPA standards closely. D.O.T.ʼs hydrostatic retest requirements apply only to charged pressure vessels which are transported in commerce in the U.S. or to foreign countries. Once the product reaches its original destination, D.O.T. rules apply only when the container is reshipped in a charged condition or being re-filled. M.S.H.A. has safety jurisdiction over mines and generally references the appropriate NFPA and D.O.T. regulations for additional guidelines on extinguisher hydrostatic testing. It will be noted that there are some gaps and overlapping in the legal requirements for periodic hydrostatic retesting of some vessels, which may be due to an oversight or other reason. However, appropriate retest intervals and test pressures have been determined for such vessels through the NFPA Committee process and/or Tyco Fire Suppression & Building Productsʼ own research and experience. In many cases, compliance to the NFPA standards may put you in compliance with OSHA (refer to the National Consensus Standards, Appendix B, Subpart L). A Tyco Fire Suppression & Building Products recommendation is indicated for each of the pressure vessels addressed by this Bulletin. Hydrostatic testing should only be performed by trained, qualified persons with suitable testing equipment and facilities. For additional guidance you are referred to CFR-49, CFR-29, NFPA-10, the current ANSUL manual “Hydrostatic Test Instructions for Portables, Wheeled Units, and Pre-engineered Systems,” Form No. F-7602 and the Compressed Gas Association phamplets “C-6,” “C-6.1” and “C-1” which cover the visual inspection and hydrostatic test methods. To secure a copy of CGA Pamphlet “C-6,” “C-6.1,” or “C-1,” contact the: Compressed Gas Association Inc. 1235 Jefferson Davis Highway Arlington, VA 22202
PERIODIC HYDROSTATIC RETEST REQUIREMENTS FOR PRESSURE VESSELS IN ANSUL N.F.P.A.
CODE OF
STD. NO.
RETEST PERIOD
TEST PRESSURE
REF. NO.*
RETEST PERIOD
ANSUL Stored Pressure Dry Chemical, FE-36, and Halon 1211 Extinguishers (Agent Tanks)
10
12 years
Factory test pressure (not to exceed 3X the normal operating pressure)
1
12 years
ANSUL Stored Pressure Water and Wet Chemical Hand Portable Extinguishers (Agent Tanks) (See note)
10
5 years
Factory test pressure (not to exceed 3X the normal operating pressure)
1
5 years
ANSUL CO2 Hand Portable Extinguishers (aluminum and steel Agent Tanks) D.O.T. 3A-1800, 3AA-1800, 3AL-1800 and 3AA-2015
10
5 years (See note)
5/3 service pressure as stamped into the cylinder
1
5 years
ANSUL Dry Chemical, Cartridge10 Operated and Wheeled Extinguishers and Spill Control Application (Agent Tanks)
12 years
Original factory test pressure as shown on the nameplate or shell
N/A
N/A
ANSUL Model 33-D AFFF Wheeled Extinguishers (Agent Tank)
10
5 years
Unspecified
N/A
N/A
ANSUL Halon 1211 Wheeled Extinguishers (D.O.T. 4BW-240 Agent Tanks)
10
Per D.O.T. marking (See notes)
Factory test pressure (not to exceed 3X the normal operating pressure)
3, 6
7 or 12 years (See Ref. No. 6)
CO2 Cartridges for 5, 10, 20 and 30 Models N2 Cartridges for 5 and 10 Low Temperature Extinguisher Models
10 None Required
1, 4
None Required
N2 Cartridges for 20 and 30 Low Temperature Extinguisher Models
10
Per D.O.T. or C.T.C. markings
2, 5
Per stamped markings 5 or 10 years
Nitrogen Cylinders for all ANSUL Wheeled Extinguishers
10
5 or 10 years
5/3 service pressure as stamped into the cylinder
2, 5
5 or 10 years
Pre-Engineered 101 Agent Tanks
17
12 years
Original factory test pressure as shown on nameplate or shell
N/A
N/A
ANSUL Model SPA-50 and IND-X (D.O.T. 4BW-500 Agent Tanks)
17
12 years
Factory test pressure (not to exceed 2X the normal operating pressure)
1, 3, 6
7 or 12 years
ANSUL R-102 Wet Chemical Agent Tanks (carbon steel and stainless tanks)
17A
12 years
Factory test pressure (not to exceed 3X the normal operating pressure)
1
12 years
ANSUL Model H-1000 and H-101 (D.O.T. 4BW-500 Agent Tanks)
12A
12 years
Factory test pressure (not to exceed 2X the normal operating pressure)
3, 6
7 or 12 years
ANSUL Model H-1000 with 3A or 3AA D.O.T. Stamp (Agent Tanks)
12/ 12A
5 years
5/3 service pressure as stamped into the cylinder
1
5 years
Pre-engineered System Cartridges —Except LT-5, LT-10 and 101-10
17/ 17A
12 years
Factory test pressure
2, 5
5 or 10 years
Pre-engineered System Cartridges —LT-5, LT-10 and 101-10
17/ 17A
1
None Required D.O.T. 3E Tank
PRESSURE VESSEL
None Required Per D.O.T. 3E Stamp
— As used in this chart, service pressure and operating pressure are the same. — Dry Powder Extinguishers should be tested at the same intervals and pressures as Dry Chemical Extinguishers.
PORTABLES, WHEELED UNITS, AND PRE-ENGINEERED VESSELS FEDERAL REGULATIONS
TYCO RECOMMENDS
TEST PRESSURE
RETEST PERIOD
TEST PRESSURE
Factory test pressure (not to exceed 2X the service pressure)
12 years
600 PSI (41.4 bar)
• Agent hose assemblies with a shut-off nozzle must be tested @ 300 psi (20.7 bar).
Factory test pressure (not to exceed 2X the service pressure)
5 years
200 PSI (13.8 bar)
• Exception: Does not apply to ANSUL ENSIGN Model WF-2 1/2 fiberglass extinguishers which were recalled in 1973. Under no circumstances are these units to be hydrostatically tested or recharged.
5/3 service pressure
5 years (See note)
5/3 service pressure
• Aluminum tanks suspected of being exposed to temperatures in excess of 350 °F (177 °C) shall be removed from service and subjected to a hydrostatic retest.
N/A
12 years
600 PSI (41.4 bar)
• Agent hose assemblies must be tested at same intervals @ 300 PSI (20.7 bar), or at service pressure, whichever is higher.
N/A
5 years
600 PSI (41.4 bar)
• Agent hose assemblies must be tested at same intervals @ 300 PSI (20.7 bar), or at service pressure, whichever is higher.
2X service pressure
7 or 12 years
480 PSI (33.1 bar)
• Agent hose assemblies must be tested at same intervals @ 300 PSI (20.7 bar).
None Required
None Required
Per stamped markings 5/3 service pressure
5 or 10 years
5/3 service pressure
5/3 service pressure
5 or 10 years
5/3 service pressure
N/A
12 years
600 PSI (41.4 bar)
• Agent hose assemblies must be tested at same intervals @ 300 PSI (20.7 bar), or at service pressure, whichever is higher.
Factory test pressure (not to exceed 2X the normal operating pressure)
7 or 12 years
1000 PSI (68.9 bar)
• Test 1 inch discharge hose and 1/4 inch actuation hose @ 1000 PSI (68.9 bar).
Factory test pressure (not to exceed 2X the normal operating pressure)
12 years
300 PSI (20.7 bar)
• Test 1/4 inch gas hose assembly @ 300 PSI (20.7 bar).
Factory test pressure (not to exceed 2X the normal operating pressure)
7 or 12 years
1000 PSI (68.9 bar)
• Test 1 inch discharge hose and 1/4 inch actuation hose @ 1000 PSI (68.9 bar).
5/3 service pressure
5 years
5/3 service pressure
Factory test pressure
12 years
Factory test pressure
NOTES
• Exempt because of size and stamp.
None Required — F actory test pressures are indicated on the extinguisher nameplat es. — Recording of hydrostatic testing shall be in accordance with NFPA-10 recommendat ions.
• LT-5-L, LT-5-R, LT-10-L, LT-10-R, 101-10 and K-101-10 exempt because of size and stamp. * See next page for references to Code of Federal Regulations.
