SAE AIR1059F

__________________________________________________________________________________________________________________________________________ SAE Technical Standards Board Rules provide that “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefrom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2020 SAE International All rights reserved. No part of this publication may be reproduced, stored in a retri system or transmitted, in any or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER Tel 877-606-7323 inside USA and Canada Tel 1 724-776-4970 outside USA Fax 724-776-0790 Email CustomerServicesae.org SAE WEB ADDRESS http//www.sae.org SAE values your . To provide feedback on this Technical Report, please visit http//standards.sae.org/AIR1059F AEROSPACE INATION REPORT AIR1059 REV. F Issued 1968-12 Reaffirmed 2008-11 Revised 2020-01 Superseding AIR1059E Oxygen Cylinder Quality, Serviceability, Maintenance Transfilling, and Marking RATIONALE Update from revision E to F mainly to clarify purity sampling requirements. 1. SCOPE This document provides guidance concerning the maintenance and serviceability of oxygen cylinders beginning with the quality of oxygen that is required, supplemental oxygen ination, handling and cleaning procedures, transfilling, and marking of serviced oxygen assemblies. This document attempts to outline in a logical sequence oxygen quality, serviceability, and maintenance of oxygen cylinders. Content of this document can also be used for refilling of oxygen cylinder while installed on aircraft, directly or through an intermediate charging port. 2. REFERENCES 2.1 Applicable Documents The following publications a part of this document to the extent specified herein. The latest issue of SAE publications shall apply. The applicable issue of other publications shall be the issue in effect on the date of the purchase order. In the event of conflict between the text of this document and references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific mption has been obtained. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel 877-606-7323 inside USA and Canada or 1 724-776-4970 outside USA, www.sae.org. AIR4071 Lubricants for Oxygen Use AIR5742 Packaging and Transportation of Oxygen Equipment ARP1176 Oxygen System and Component Cleaning AS8010 Aviators Breathing Oxygen Purity Standard SAE INTERNATIONAL AIR1059F Page 2 of 13 2.1.2 CGA Publications Available from CGA, 14501 George Carter Way, Suite 103, Chantilly, VA 20151, Tel 703-788-2700, . C-6 Standards for Visual Inspection of Steel Compressed Gas Cylinders C-6.1 Standard for Visual Inspection of High Pressure Aluminum Alloy Compressed Gas Cylinders C-6.2 Standard for visual Inspection and Requalification of Fiber Reinforced High Pressure Cylinders P-1 Standard for Safe Handling of Compressed Gases in Containers P-2.5 Standard for the transfilling of High Pressure Gaseous Oxygen Used for Respiration P-15 Filling of Industrial and Medical Nonflammable Compressed Gas Cylinders P-38 Guidelines for Dving Cylinders V-1 Standards for Compressed Gas Cylinder Valve Outlet and Inlet Connections 2.1.3 ASTM Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel 610-832-9585, www.astm.org. ASTM G63 Standard Guide for uating Nonmetallic Materials for Oxygen Service ASTM G94 Standard Guide for uating Metals for Oxygen Service 2.2 Related Publications The following publications are provided for ination purposes only and are not a required part of this SAE Aerospace Technical Report. 2.2.1 U.S. Government Publications Copies of these documents are available online at https//quicksearch.dla.mil. Any Applicable U.S. DOT Special Permits DOT-SP 8162 PHMSA example of a special permit for structural composites 49 CFR 180-209 Requirements for Requalification of Specification Cylinders 49 CFR 173.301 General Requirements for Shipment of Compressed Gases and other Hazardous Material in Cylinders UN Pressure Receptacles and Spherical Pressure Vessels 49 CFR 173.302 Filling of Cylinders with Non-Liquefied Permanent Compressed Gases or Absorbed Gases OSHA 1910-253 Oxygen Fuel Gas Welding and Cutting MIL-PRF-27210 Aviators Breathing Oxygen, Liquid and Gas MIL-PRF-25567 Leak Detection Compound, Oxygen Systems SAE INTERNATIONAL AIR1059F Page 3 of 13 3. INTRODUCTION Recharging of portable and fixed oxygen cylinders by the unauthorized user is a practice both condemned and discouraged by the Compressed Gas Association CGA and the National Fire Protection Association NFPA. Their condemnation is based on the firm conviction of the majority of the Association members that “transfilling” an oxygen cylinder by “unqualified” personnel is basically unsafe and must not be pered. In the United States, the DOT regulations govern the ownership of the cylinder and authorization to fill it. In Canada, Transport Canada Transportation of Dangerous Goods Regulations control the filling of cylinders refer to CGA pamphlet P-1. In other countries, other authorities and regulations may apply. All personnel assigned to transfilling must be trained and qualified in the inherent hazards of high pressure aviation oxygen and knowledgeable in this equipment. WARNING Improper use, handling, or maintenance of oxygen equipment may result in serious injury or death. Oxygen equipment is to be serviced including transfilling only in accordance with applicable written service procedures available from the original equipment manufacturer and in the case of transfilling in compliance with CGA Pamphlet P-2.5 and with local regulations. Only service technicians trained in the inherent hazards of high pressure aviation oxygen and knowledgeable in this equipment may service this equipment. Commercial airlines, aircraft manufacturers, and aircraft service stations have been involved in, and will continue to follow, the practice of filling the portable oxygen units and fixed oxygen cylinders in commercial and general aviation. A standardized procedure should be established for charging high pressure oxygen cylinders in those aviation facilities which are required by circumstances to per oxygen cylinder filling. This document starts with an overview of oxygen cylinder requirements. 4. OXYGEN COMPOSITION REQUIREMENTS 4.1 Oxygen Quality All oxygen gas purchased or manufactured for filling aviators breathing oxygen cylinders shall comply with aviators breathing oxygen per AS8010 or Military Specification MIL-PRF-27210. When oxygen is purchased for this purpose, the oxygen manufacturers delivery ticket shall bear a certification that oxygen purity cons to the above specifications and prescribed tests under the above specifications have been pered prior to delivery. Records of such delivery shall be maintained by the cylinder filler for a period of 5 years, minimum. 4.2 Test Procedure Chemical tests for various gas concentrations have evolved and been replaced by the use of calibrated gas analyzers and these are the preferred due to ease of operation. The chemical s are still an acceptable and have been retained in this document for historical reference. All chemical tests shall be made with analytical reagent grade chemicals and distilled water. Samples taken in accordance with Section 5 shall be tested for purity, using a approved by the procuring activity such as 4.3; for odor, in accordance with 4.5; for moisture, in accordance with 4.4; for pressure, in accordance with 4.6; and for leakage, in accordance with 4.8. 4.3 Purity Oxygen gas in serviced cylinders shall contain not less than 99.5 oxygen by volume, when tested. Samples taken for test shall be tested for conance to AS8010 or MIL-PRF-27210. The test for oxygen concentration has evolved from chemical analysis to the use of calibrated oxygen analyzers. The use of an oxygen analyzer that has a certified calibration within due date is recommended as an acceptable means to determine the level of oxygen concentration. The chemical analysis , while still an acceptable of analysis, is provided as a historical reference. Place a sufficient quantity of mercury in a 100 cm 3 calibrated gas measuring burette provided with a two-way stopcock and a two-way outlet, and properly connected with a liquid leveling tube. Connect one of the outlet tubes of the burette with a gas pipette of suitable capacity. Place in the pipette a coil of copper wire which extends to the uppermost portion of the bulb, and add about 125 cc of ammonium chloride-ammonium hydroxide test solution made by mixing equal volumes of water and 27 concentrated ammonia; then saturate with ammonium chloride. Draw the liquid free from air bubbles through the capillary opening connection and stopcock opening in the burette by reducing the pressure in the burette tube and opening the stopcock controlling connection with the gas pipette. Then close the stopcock. SAE INTERNATIONAL AIR1059F Page 4 of 13 Having completely filled the burette, the other stopcock opening, and the other intake tube with mercury, draw into the burette exactly 100 cc of oxygen by reducing the pressure in the tube. Close the stopcock. Increase the pressure on the oxygen in the burette tube, and open the stopcock controlling the connection with the gas pipette. Force the entire volume of gas into the pipette. Close the stopcock, and rock the pipette gently, providing frequent contact of the liquid, gas, and copper spiral. At the end of 15 minutes, most of the gas will have been absorbed by the liquid. At this time, to facilitate absorption of the last portion of the oxygen, draw some of the liquid into the burette tube, and force the residual gas back upon the surface of the liquid in the gas pipette. Again, rock the pipette until no further diminution in the volume of the gas occurs. Draw the residual gas, if any, into the burette tube, and measure its volume. The volume of gas remaining undissolved shall not exceed 1/2 cc. The ammonium chloride-ammonium hydroxide solution should be used for leveling purposes if desired. 4.4 Moisture The moisture content shall be determined by use of an electrolytic type moisture meter or other or equipment satisfactory for the purpose. The oxygen gas in serviced cylinders shall contain no more than 0.02 mg of water per liter of gas at 21 C 70 F and 760 mm Hg 1 MPa or 1013 mbar. This level of moisture is equivalent to 25 ppm by volume or a -53 C -64 F dew point. 4.5 Odor Each cylinder serviced, as well as those selected as specified in Section 5, shall be subjected to the following test The cylinder valve shall be slowly opened enough to allow a small amount of oxygen to flow. No smell should exist since pure oxygen is odorless and tasteless cylinders received for refill which have an odor present shall be visually inspected internally, cleaned and dried before filling see 4.9. Filled cylinders having an odor shall be rejected. 4.6 Filling Pressure The cylinder shall be filled to the pressure at 21 C 70 F as required by the markings on the cylinder or required by the equipment manufacturer and indicated by a decal, label, or other means. On steel cylinders the maximum filling pressure is stamped on the shoulder of the cylinder; as for example, DOT 3AA 1800 signifies a filling pressure of 1800 psig 12.4 MPa. On fully wrapped composite cylinders, the maximum filling pressure is marked on a label imbedded in the overwrap. For example, a marking such as DOT SP-XXXX 1850 signifies a filling pressure of 1850 psig 12.76 MPa. The actual cylinder pressure charge shall be determined by a calibrated lab type gauge with an accuracy of 5 of the filling pressure. NOTE Cylinders should be refilled slowly enough see here after to avoid heat of rapid compression. Sufficient time must be allowed for the gas temperature to stabilize to 21 C 70 F before checking the pressure to avoid need to recheck pressure after cool-down of cylinder 1 MPa 10 bar. It is suggested that the operator consult with the cylinder manufacturer for safe maximum temperature ratings prior to any cylinder refill. Maximum refilling pressure rate can be adapted to the context. A maximum rate of 1.4 MPa 200 psi per minute is a usual practical value. Higher rates may be acceptable depending on the exact configuration and means certified by the operator i.e., optimized for various volumes, tank material, temperature controlled means 4.7 Pressure Gauge Accuracy Cylinders which have pressure gauges as an integral part of the valve assembly shall be tested as follows. Check that cylinder gauge reading is within 3448 hPa 50 psi of the gauge reading on the refilling equipment. Inaccurate gauges should be replaced with gauges of the same equipment manufacturers part number. Only gauges marked “use no oil” which have been cleaned for oxygen service should be used. NOTE On some cylinder assemblies incorporating an integral pressure reducer, a filler valve is used which has a pressure drop of 1724 hPa 25 psig or higher psig. This type of assembly requires that the gauge be removed for test or an allowance be made for the pressure drop. SAE INTERNATIONAL AIR1059F Page 5 of 13 4.8 Leakage Each filled cylinder shall be tested for leakage. Various acceptable s are available Either by brushing an approved oxygen compatible leak check solution refer to MIL-PRF-25567 over the cylinder and all portions of the valve, Or by submerging in water the cylinder and those portions of the valve and gauge which will not be damaged by submersion, Or by checking pressure decay with time if the cylinder is equipped with a pressure gauge or transducer and by giving caution to the measurement accuracy and temperature correction due to ambient temperature variation, Or by weight loss measurement with time. Continued bubbling indicates leakage and is cause for rejection. This must be distinguished from bubbling caused by the escape of air entrapped in crevices and corners. Also, a test shall be conducted with outlet capped and “valve opened.” Any leakage, visible within 5 minutes, around valve stem or packing gland is cause for rejection. If cylinder valve is equipped with a