Post by Travis on Jan 31, 2013 10:11:02 GMT -3.5
Any questions, PM me.
Short Version:
-A CO2 tank has to be checked every 5 years, unless it is a 9oz steel tank. The ones with the round bottom.
-Any steel tank (normally has a round bottom) must be tested every 5 years, and has an unlimited life span
-Any non-steel co2 tank (most of them are aluminum) need to be tester every 5 years, and have a 15 year life span
- ALL hpa tanks need to be tested every 3 years in Canada (unless it says 5 years on the tank. In the US it is often 5, but only 3 in Canada. Once it has been checked, it is good for 5 years.
- Steel HPA tanks need to be tested every 5 years unless it has 3HT stamped on it, or a magnet sticks to it, which means it must be tested every 3 years
- HPA tanks have a 15-25 year life span depending
- All HPA and CO2 tanks MUST HAVE A TC STAMP. IT will be read something like : TC-SU 5303 or something similar.
FRONTLINE IS TIGHTENING THIS UP. IF YOUR TANK HAS NO TC, IS OUT OF HYDRO, OR HAS VISUAL DAMAGE WE WILL NOT BE FILLING IT. Frontline has the right to refuse to fill any tank they consider unsafe.
Long Version:
I have decided to compile all of the information regarding high pressure air systems in use in paintball into one, easy to read, resource. I encourage everyone to take a read through this as it not only reinforces common safety regulations, but it also addresses several issues of false information that is common in the industry. All graphics were taken from hydrotester.com
I worked on this today during a boring class and there may be mistakes of some sort, so if you notice anything, just PM me.
If this could be stickied (and the other similar threads deleted as they are not as easy to read as this), it would be great. I will be adding to this as well in the near future.
- Matthew
MAINTENANCE
CO2 Tanks
Any valve work conducted on any pressurized vessel should be conducted by trained personnel. Any information presented here is for informational purposes. Use at own risk.
The burst disk is the primary safety feature (designed failure point) on any pressurized paintball tank, so tampering with this device is strongly discouraged. The burst disk is designed to fail and vent the contents of the tank before the valve breaks or the tank itself rupture. Make sure you use a burst disk that is designed for use on a CO2 tank NOT a HPA tank. IF YOU TAMPER WITH THIS, YOU AND EVERYONE AROUND YOU WILL DIE. In the event that the burst disk is blown, or the disk is unscrewed to vent the tank before conducting work, make sure to leave it in a secure and safe place for several hours before continuing. The rapid vaporization of CO2 will cause a chunk of dry ice CO2 to form inside the tank. This can re-pressurize the tank if the tank is re-sealed.
A CO2 requires a burst disk with a pressure range from 1800 to 2500 psi
The best way to remove valves from any tank is to run it under hot water for around 10 minutes if loctite was used. This will soften the thread locking compound enough to unscrew the tank. DO NOT use heat guns or any hot temperature source in this procedure as the heat can compromise the structural integrity of the tank itself.
When reinstalling a tank valve, ensure that any thread locker is remove from the threads prior to starting. If you choose to use loctite, blue is recommended as opposed to red. Red loctite requires a temperature to soften that can damage the tank itself. Take care to only use loctite on the first few threads, and ENSURE THAT THE SAFETY VENTS ARE NOT CLOGGED WHEN REINSTALLING THE VALVE. These vents will empty the contents of the tank if the tank unscrews from the valve instead of the valve from the ASA. PEOPLE HAVE DIED BECAUSE OF THIS.
The safest way to reinstall a valve on a tank is to NOT USE LOCTITE AT ALL. This prevents any issue with the safety vents and trying to remove the valve for future work. The process described by Catalina Cylinders for this work is to torque the valve onto the tank body using FOURTY (40) to FIFTY (50) POUNDS OF TORQUE (use a torque wrench). This is the recommend procedure straight from the manufacturer, so it should be followed.
TORQUING A TANK BY HAND, OR INDISCRIMINATELY USING A WRENCH WITH NO REGARD TO FORCE IS UNSAFE.
HYDROTESTING REGULATIONS
Carbon Dioxide (CO2) Tanks
There are three major types of CO2 tanks used in paintball applications, and they differ in their material of construction and thus have slight differences in their hydro testing requirements. The tanks types used are: Aluminum, Steel, and Chromoly.
Aluminum
These are now the most common tanks used for CO2 in the paintball industry. The easiest way to determine if a CO2 tank is made out of aluminum, especially if you are unfamiliar with these tanks, is to use a magnet. A magnet will not stick to these tanks. The regulation for this type of tank is as follows:
All Aluminum CO2 tanks must be hydrotested every 5 years, with unlimited lifespan.
This means if you keep testing them and they keep passing the test, you can use them indefinitely. However, the cost of hydrotesting a CO2 tank is generally higher than the cost of a new tank, so unless the tank has some significance due to being an odd size or special anno, they are usually discarded.
Steel
These tanks were the most common material for CO2 tanks, but have fallen into limited use as they are more prone to rusting compared to Aluminum. They are easy to identify as they are usually a different design than Aluminum and are magnetic. The regulation on these types of tanks is as follows:
All Steel CO2 tanks must be hydrotested every 5 years, with unlimited lifespan.
The above notes for Aluminum tank applies to Steel tanks.
Cromoly
This term is sort for a material known as chromium-molybdenum steel, which is a low alloy steel. This means that it is more durable and stronger than conventional steel used in other tanks. These types of tanks are not as common as the other types. The regulation of these types of tanks is as follows:
All Chromoly CO2 tanks must be hydrotested every 5 years, with unlimited lifespan.THERE IS A BELIEF THAT THESE TANKS ARE EXEMPT AND ONLY REQUIRE A VISUAL INSPECTION PRIOR TO FILLING, BUT THIS IS FALSE.
The above notes for Aluminum tank applies to Cromoly tanks.
2 and 2 Rule
The "two and two rule" states that any CO2 tank that is less than 2 feet in length and 2 inches in diameter is exempt from hydro testing. This rule has been accepted by the US Department of Transport (DOT), but NOT Transport Canada (TC) as of yet. Thus, THIS RULE DOES NOT APPLY IN CANADA. In the event that this rule is accepted, these tanks should still be visually inspected to ensure there is no damage. It is YOUR responsibility to ensure that the tank is not damaged.
High Pressure Air (HPA) Tank
There are three primary materials used in the construction of HPA tanks for use in paintball applications. They are: Fiber Wrapped, Aluminum, and Steel. Fiber Wrapped tanks are actually steel or aluminum tanks that have been wrapped in fibrous material.
HPA Burst Disks
Because of the different pressures available for paintball HPA systems, it is important to ensure that the correct burst disk is used. The following are standards for 3000 psi and 4500 psi tanks:
3000 psi tank = 3500 psi burst disk
4500 psi tank = 5000 psi burst disk
DO NOT SWITCH THESE. THE 3500 DISK ON A 4500 TANK WILL ALWAYS BURST AND THE 5000 DISK ON A 3000 TANK MAY NOT BURST BEFORE THE TANK RUPTURES
Reading HPA Label
Fiber Wrapped
All fiber-wrapped tanks are to be hydrotested every 3 years, unless the manufacturer specifically indicates ON THE BOTTLE that hydrotesting is due at 5 years. All fiber-wrapped tanks have a maximum lifespan of 15 years, no exceptions. After 15 years, the tank must be deactivated and discarded. It is encouraged that the tank have the bottom drilled out preventing future pressurization or use.
Steel/Aluminum
All steel and aluminum HPA tanks are to be tested every 5 years, with an unlimited lifespan. The only exception to this rule is for steel tanks stamped 3HT, which must be tested every 3 years and have a 24 year lifespan.
Exemption Codes
There are some "E" codes stamped on some fiber-wrapped HPA bottles. Many people believe that if their bottle is stamped with an "E" code it means they are exempt from testing, this is not true. It means that bottle falls under an exemption from the blanket rule in some specification, but that exemption may or may not address the hydrotest date. Here are the only listed "E" codes for fiber-wrapped tanks on the DOT site, and how they will affect your bottle.
E-07277 - manufacterer SCI, to be tested every 3 years, 15 year service life. This exemption deals with the manufacturing process, not the hydrotest schedule.
E-09634 - manufacturer Luxfer, to be tested every 3 years, 15 year service life. This exemption deals with the manufacturing process, not the hydrotest schedule.
E-10915 - manufacturer Luxfer, may be changed to 5-year schedule, this will be explained below.
E-10945, manufacturer SCI, may be changed to 5-year schedulue, as explained below
E-11005, manufacturer Careton Tech, to be tested every 3 years, 15 year service life. This exemption deals with the manufacturing process, not the hydrotest schedule.
E-11194, manufacturer Careton Tech, may be changed to 5 year schedule, as explained below
E-12479, manufacturer Luxfer, to be tested every 3 years, 15 year service life. This exemption deals with the manufacturing process, not the hydrotest schedule.
On some Scott CO2 bottles E-8096: exempts these bottles from ever needing to be tested, for their service life of 15 years. These are for 16 ounce chrome-moly tanks, the exemption will expire on October 31, 2005. After that date, if the exemption is not renewed by the manufacturer, they will have to be hydroed.
4500 psi Regulator on a 3000 psi Tank
You can use a 4500 psi regulator on a 3000 psi tank as long as the following precautions are used:
1. The regulator must have the burst disk replaced with one for a 3000 psi tank ( 3500 psi burst disk). If not, the burst disk may not fail before the tank fails as it is designed for much higher pressure.
2. The tank must never be filled more with than 3000 psi. For all intents and purposes, this is a 3000 psi tank regardless of the regulator used (assuming the burst disk is replaced).
Oiling Procedure
It is very important to never introduce any oil based product into the pressured system upstream of the regulator. The combination of heat (caused by filling), oil (a chemical substance), and oxygen (21% atmospheric is still classified as "clean oxygen") can cause ignition. In a pressurized vessel such as an HPA tank this can cause rupture and/or detonation. This means that you must:
1. NEVER oil the HPA tank fill nipple for any reason.
2. NEVER oil the fill station female disconnect for any reason.
3. ENSURE the cleanliness of both fittings on a regular basis.
It is also not just oil that can cause ignition. According to XS SCUBA (http://www.xsscuba.com/tank_alum_faq_oxygen.html), the following materials can and will cause ignition:
Machining oils (including residual oil film)
Hydrocarbon-based grease and lubricants (including compressor oil)
Some soaps, detergents, solvents and cleaning solutions, especially those that contain organic compounds
Skin lotions and emollients and cosmetics
Sun-tanning oils and lotions
Human skin oil and bodily fluids
Insects and insect body parts
Paint, wax, and marking crayons
Carbon dust from filtration systems
Metal fines, filings, scale and burrs
Chrome chips (usually from valves and other chrome-plated parts)
Rust particles and dust
Metallic oxides in general
Airborne soot and dust
Pipe thread sealants
Residue from soapy water and leak-detection fluids used to check for leaks
Lint from cloths used in cleaning
Any other material containing organic compounds and hydrocarbons
The above two are bolded as this can be a concern when the whip/disconnect becomes worn.
DAMAGE INFORMATION
CO2 Tank Damage
CO2 tanks must be checked for any sign of external damage such as dents, cracks, wear, etc. Due to the low price of CO2 systems, it is not worth the risk to you and everyone around you to continue using a worn CO2 tank regardless of age.
HPA Tank Damage
It is very important to check the condition of your own tank regularly as you, the user, will be the one likely to be affected by a catastrophic failure in your pressure system. A fiber wrapped tank is essentially (if not properly used and respected) a 4500 psi bomb being held to your chest. The following chart explains what to do regarding wear/damage on your fiber wrapped tank:
Short Version:
-A CO2 tank has to be checked every 5 years, unless it is a 9oz steel tank. The ones with the round bottom.
-Any steel tank (normally has a round bottom) must be tested every 5 years, and has an unlimited life span
-Any non-steel co2 tank (most of them are aluminum) need to be tester every 5 years, and have a 15 year life span
- ALL hpa tanks need to be tested every 3 years in Canada (unless it says 5 years on the tank. In the US it is often 5, but only 3 in Canada. Once it has been checked, it is good for 5 years.
- Steel HPA tanks need to be tested every 5 years unless it has 3HT stamped on it, or a magnet sticks to it, which means it must be tested every 3 years
- HPA tanks have a 15-25 year life span depending
- All HPA and CO2 tanks MUST HAVE A TC STAMP. IT will be read something like : TC-SU 5303 or something similar.
FRONTLINE IS TIGHTENING THIS UP. IF YOUR TANK HAS NO TC, IS OUT OF HYDRO, OR HAS VISUAL DAMAGE WE WILL NOT BE FILLING IT. Frontline has the right to refuse to fill any tank they consider unsafe.
Long Version:
I have decided to compile all of the information regarding high pressure air systems in use in paintball into one, easy to read, resource. I encourage everyone to take a read through this as it not only reinforces common safety regulations, but it also addresses several issues of false information that is common in the industry. All graphics were taken from hydrotester.com
I worked on this today during a boring class and there may be mistakes of some sort, so if you notice anything, just PM me.
If this could be stickied (and the other similar threads deleted as they are not as easy to read as this), it would be great. I will be adding to this as well in the near future.
- Matthew
MAINTENANCE
CO2 Tanks
Any valve work conducted on any pressurized vessel should be conducted by trained personnel. Any information presented here is for informational purposes. Use at own risk.
The burst disk is the primary safety feature (designed failure point) on any pressurized paintball tank, so tampering with this device is strongly discouraged. The burst disk is designed to fail and vent the contents of the tank before the valve breaks or the tank itself rupture. Make sure you use a burst disk that is designed for use on a CO2 tank NOT a HPA tank. IF YOU TAMPER WITH THIS, YOU AND EVERYONE AROUND YOU WILL DIE. In the event that the burst disk is blown, or the disk is unscrewed to vent the tank before conducting work, make sure to leave it in a secure and safe place for several hours before continuing. The rapid vaporization of CO2 will cause a chunk of dry ice CO2 to form inside the tank. This can re-pressurize the tank if the tank is re-sealed.
A CO2 requires a burst disk with a pressure range from 1800 to 2500 psi
The best way to remove valves from any tank is to run it under hot water for around 10 minutes if loctite was used. This will soften the thread locking compound enough to unscrew the tank. DO NOT use heat guns or any hot temperature source in this procedure as the heat can compromise the structural integrity of the tank itself.
When reinstalling a tank valve, ensure that any thread locker is remove from the threads prior to starting. If you choose to use loctite, blue is recommended as opposed to red. Red loctite requires a temperature to soften that can damage the tank itself. Take care to only use loctite on the first few threads, and ENSURE THAT THE SAFETY VENTS ARE NOT CLOGGED WHEN REINSTALLING THE VALVE. These vents will empty the contents of the tank if the tank unscrews from the valve instead of the valve from the ASA. PEOPLE HAVE DIED BECAUSE OF THIS.
The safest way to reinstall a valve on a tank is to NOT USE LOCTITE AT ALL. This prevents any issue with the safety vents and trying to remove the valve for future work. The process described by Catalina Cylinders for this work is to torque the valve onto the tank body using FOURTY (40) to FIFTY (50) POUNDS OF TORQUE (use a torque wrench). This is the recommend procedure straight from the manufacturer, so it should be followed.
TORQUING A TANK BY HAND, OR INDISCRIMINATELY USING A WRENCH WITH NO REGARD TO FORCE IS UNSAFE.
HYDROTESTING REGULATIONS
Carbon Dioxide (CO2) Tanks
There are three major types of CO2 tanks used in paintball applications, and they differ in their material of construction and thus have slight differences in their hydro testing requirements. The tanks types used are: Aluminum, Steel, and Chromoly.
Aluminum
These are now the most common tanks used for CO2 in the paintball industry. The easiest way to determine if a CO2 tank is made out of aluminum, especially if you are unfamiliar with these tanks, is to use a magnet. A magnet will not stick to these tanks. The regulation for this type of tank is as follows:
All Aluminum CO2 tanks must be hydrotested every 5 years, with unlimited lifespan.
This means if you keep testing them and they keep passing the test, you can use them indefinitely. However, the cost of hydrotesting a CO2 tank is generally higher than the cost of a new tank, so unless the tank has some significance due to being an odd size or special anno, they are usually discarded.
Steel
These tanks were the most common material for CO2 tanks, but have fallen into limited use as they are more prone to rusting compared to Aluminum. They are easy to identify as they are usually a different design than Aluminum and are magnetic. The regulation on these types of tanks is as follows:
All Steel CO2 tanks must be hydrotested every 5 years, with unlimited lifespan.
The above notes for Aluminum tank applies to Steel tanks.
Cromoly
This term is sort for a material known as chromium-molybdenum steel, which is a low alloy steel. This means that it is more durable and stronger than conventional steel used in other tanks. These types of tanks are not as common as the other types. The regulation of these types of tanks is as follows:
All Chromoly CO2 tanks must be hydrotested every 5 years, with unlimited lifespan.THERE IS A BELIEF THAT THESE TANKS ARE EXEMPT AND ONLY REQUIRE A VISUAL INSPECTION PRIOR TO FILLING, BUT THIS IS FALSE.
The above notes for Aluminum tank applies to Cromoly tanks.
2 and 2 Rule
The "two and two rule" states that any CO2 tank that is less than 2 feet in length and 2 inches in diameter is exempt from hydro testing. This rule has been accepted by the US Department of Transport (DOT), but NOT Transport Canada (TC) as of yet. Thus, THIS RULE DOES NOT APPLY IN CANADA. In the event that this rule is accepted, these tanks should still be visually inspected to ensure there is no damage. It is YOUR responsibility to ensure that the tank is not damaged.
High Pressure Air (HPA) Tank
There are three primary materials used in the construction of HPA tanks for use in paintball applications. They are: Fiber Wrapped, Aluminum, and Steel. Fiber Wrapped tanks are actually steel or aluminum tanks that have been wrapped in fibrous material.
HPA Burst Disks
Because of the different pressures available for paintball HPA systems, it is important to ensure that the correct burst disk is used. The following are standards for 3000 psi and 4500 psi tanks:
3000 psi tank = 3500 psi burst disk
4500 psi tank = 5000 psi burst disk
DO NOT SWITCH THESE. THE 3500 DISK ON A 4500 TANK WILL ALWAYS BURST AND THE 5000 DISK ON A 3000 TANK MAY NOT BURST BEFORE THE TANK RUPTURES
Reading HPA Label
Fiber Wrapped
All fiber-wrapped tanks are to be hydrotested every 3 years, unless the manufacturer specifically indicates ON THE BOTTLE that hydrotesting is due at 5 years. All fiber-wrapped tanks have a maximum lifespan of 15 years, no exceptions. After 15 years, the tank must be deactivated and discarded. It is encouraged that the tank have the bottom drilled out preventing future pressurization or use.
Steel/Aluminum
All steel and aluminum HPA tanks are to be tested every 5 years, with an unlimited lifespan. The only exception to this rule is for steel tanks stamped 3HT, which must be tested every 3 years and have a 24 year lifespan.
Exemption Codes
There are some "E" codes stamped on some fiber-wrapped HPA bottles. Many people believe that if their bottle is stamped with an "E" code it means they are exempt from testing, this is not true. It means that bottle falls under an exemption from the blanket rule in some specification, but that exemption may or may not address the hydrotest date. Here are the only listed "E" codes for fiber-wrapped tanks on the DOT site, and how they will affect your bottle.
E-07277 - manufacterer SCI, to be tested every 3 years, 15 year service life. This exemption deals with the manufacturing process, not the hydrotest schedule.
E-09634 - manufacturer Luxfer, to be tested every 3 years, 15 year service life. This exemption deals with the manufacturing process, not the hydrotest schedule.
E-10915 - manufacturer Luxfer, may be changed to 5-year schedule, this will be explained below.
E-10945, manufacturer SCI, may be changed to 5-year schedulue, as explained below
E-11005, manufacturer Careton Tech, to be tested every 3 years, 15 year service life. This exemption deals with the manufacturing process, not the hydrotest schedule.
E-11194, manufacturer Careton Tech, may be changed to 5 year schedule, as explained below
E-12479, manufacturer Luxfer, to be tested every 3 years, 15 year service life. This exemption deals with the manufacturing process, not the hydrotest schedule.
On some Scott CO2 bottles E-8096: exempts these bottles from ever needing to be tested, for their service life of 15 years. These are for 16 ounce chrome-moly tanks, the exemption will expire on October 31, 2005. After that date, if the exemption is not renewed by the manufacturer, they will have to be hydroed.
4500 psi Regulator on a 3000 psi Tank
You can use a 4500 psi regulator on a 3000 psi tank as long as the following precautions are used:
1. The regulator must have the burst disk replaced with one for a 3000 psi tank ( 3500 psi burst disk). If not, the burst disk may not fail before the tank fails as it is designed for much higher pressure.
2. The tank must never be filled more with than 3000 psi. For all intents and purposes, this is a 3000 psi tank regardless of the regulator used (assuming the burst disk is replaced).
Oiling Procedure
It is very important to never introduce any oil based product into the pressured system upstream of the regulator. The combination of heat (caused by filling), oil (a chemical substance), and oxygen (21% atmospheric is still classified as "clean oxygen") can cause ignition. In a pressurized vessel such as an HPA tank this can cause rupture and/or detonation. This means that you must:
1. NEVER oil the HPA tank fill nipple for any reason.
2. NEVER oil the fill station female disconnect for any reason.
3. ENSURE the cleanliness of both fittings on a regular basis.
It is also not just oil that can cause ignition. According to XS SCUBA (http://www.xsscuba.com/tank_alum_faq_oxygen.html), the following materials can and will cause ignition:
Machining oils (including residual oil film)
Hydrocarbon-based grease and lubricants (including compressor oil)
Some soaps, detergents, solvents and cleaning solutions, especially those that contain organic compounds
Skin lotions and emollients and cosmetics
Sun-tanning oils and lotions
Human skin oil and bodily fluids
Insects and insect body parts
Paint, wax, and marking crayons
Carbon dust from filtration systems
Metal fines, filings, scale and burrs
Chrome chips (usually from valves and other chrome-plated parts)
Rust particles and dust
Metallic oxides in general
Airborne soot and dust
Pipe thread sealants
Residue from soapy water and leak-detection fluids used to check for leaks
Lint from cloths used in cleaning
Any other material containing organic compounds and hydrocarbons
The above two are bolded as this can be a concern when the whip/disconnect becomes worn.
DAMAGE INFORMATION
CO2 Tank Damage
CO2 tanks must be checked for any sign of external damage such as dents, cracks, wear, etc. Due to the low price of CO2 systems, it is not worth the risk to you and everyone around you to continue using a worn CO2 tank regardless of age.
HPA Tank Damage
It is very important to check the condition of your own tank regularly as you, the user, will be the one likely to be affected by a catastrophic failure in your pressure system. A fiber wrapped tank is essentially (if not properly used and respected) a 4500 psi bomb being held to your chest. The following chart explains what to do regarding wear/damage on your fiber wrapped tank: