Support For Catalina Cylinders Clientele

In CGA pamphlet C-6.1, Standards for Visual Inspection of High Pressure Aluminum Compressed Gas Cylinders, it states in section 4.2 that cuts or digs are acceptable to the following limits:

1. Unknown wall thickness, maximum dig = .031″ deep
2. Known wall thickness, maximum dig = 15% of minimum design wall thickness.a) A dig in the sidewall could be:

   .320″ (min side wall) x .15% = .048″ deep

   b) A dig in the center of the base (the thinnest part of the base) could be:

   .515 (min base) x .15% = .077″ deep

   c) A dig in the radius and footring at the bottom of the cylinder could be:

   = * .128″ (1/8″) deep

   * This dig cannot extend up into the sidewall.

3. The length of the dig must be less than 6.0″.

The Department of Transportation (DOT) and Transport Canada (TC) require that cylinders made in compliance to their specifications be marked on the crown with certain information. Over the years the format used by Catalina Cylinders and Catalina East Division to display these markings has changed a few times. Shown below is an example of the current crown marking stamped on the standard 20 # CO₂ cylinders manufactured at Catalina Cylinders, Garden Grove, CA. Under the example of the crown marking is a list of each of the specific crown markings, followed by a brief explanation of that marking. The descriptions of the markings are the same regardless of the different stamping formats used over the years .

Example of crown markings on a 20 # CO₂ Cylinder:

DOT-3AL1800FXXXXXXX M4002 07C08 B20 U18 T25.2LB TC-3ALM124 T11.5KG CATALINA

Marking		Description
DOT-3AL		The U.S. regulatory authority, the Department of Transportation (DOT), and specification, 3AL, to which the cylinder is manufactured in compliance(required mark).
1800		The service pressure, in pounds per square inch (psi), of the cylinder (required mark).
FXXXXXXX		The serial number of the cylinder. For Catalina Cylinders, the serial number prefix of “F” is specific to the 20# CO2 cylinders followed by a seven digit number.
M4002		The M-number or Manufacturers Number issued by the DOT to the manufacturer, Catalina Cylinders.
07C08		The original hydrostatic test date of the cylinder, month followed by year, performed at the time of manufacture of the cylinder. The C represents the symbol of the Independent Inspection Agency (IIA) performing the inspection of and certifying the acceptance of the cylinder at the time of manufacture (required mark).
B20		The cylinder identifier (product name). It identifies the market, “B” for beverage, and capacity “20” for a capacity of 20# of CO2 charge, of the cylinder.
U18		The cylinder outlet thread designation as specified in CGA TB-16.
T25.2LB or TW25.0LBS		The tare weight (in lbs.) of the empty cylinder package. The empty cylinder package includes the cylinder, the valve, the carrying handle and the snap ring (required mark).
TC-3ALM		The Canadian regulatory authority, Transport Canada (TC), and specification, 3ALM, to which the cylinder is manufactured in compliance (required mark).
124		The service pressure of the cylinder expressed in metric units, bars (required mark).
CATALINA		The name of the manufacturer of the cylinder.
T11.5KG		The metric tare weight (in kgs) of the empty cylinder package. The empty cylinder package includes the cylinder, the valve, the carrying handle and the snap ring.

The Department of Transportation (DOT) and Transport Canada (TC) require that cylinders made in compliance to their specifications be marked on the crown with certain information. Over the years the format used by Catalina Cylinders and Catalina East Division to display these markings has changed a few times. Shown below is an example of the current crown marking stamped on the standard 20 # CO₂ cylinders manufactured at Catalina Cylinders, Garden Grove, CA. Under the example of the crown marking is a list of each of the specific crown markings, followed by a brief explanation of that marking. The descriptions of the markings are the same regardless of the different stamping formats used over the years .

Example of crown markings on a 20 # CO₂ Cylinder:

DOT-3AL1800FXXXXXXX M4002 07C08 B20 U18 T25.2LB TC-3ALM124 T11.5KG CATALINA

Marking		Description
DOT-3AL		The U.S. regulatory authority, the Department of Transportation (DOT), and specification, 3AL, to which the cylinder is manufactured in compliance(required mark).
1800		The service pressure, in pounds per square inch (psi), of the cylinder (required mark).
FXXXXXXX		The serial number of the cylinder. For Catalina Cylinders, the serial number prefix of “F” is specific to the 20# CO2 cylinders followed by a seven digit number.
M4002		The M-number or Manufacturers Number issued by the DOT to the manufacturer, Catalina Cylinders.
07C08		The original hydrostatic test date of the cylinder, month followed by year, performed at the time of manufacture of the cylinder. The C represents the symbol of the Independent Inspection Agency (IIA) performing the inspection of and certifying the acceptance of the cylinder at the time of manufacture (required mark).
B20		The cylinder identifier (product name). It identifies the market, “B” for beverage, and capacity “20” for a capacity of 20# of CO2 charge, of the cylinder.
U18		The cylinder outlet thread designation as specified in CGA TB-16.
T25.2LB or TW25.0LBS		The tare weight (in lbs.) of the empty cylinder package. The empty cylinder package includes the cylinder, the valve, the carrying handle and the snap ring (required mark).
TC-3ALM		The Canadian regulatory authority, Transport Canada (TC), and specification, 3ALM, to which the cylinder is manufactured in compliance (required mark).
124		The service pressure of the cylinder expressed in metric units, bars (required mark).
CATALINA		The name of the manufacturer of the cylinder.
T11.5KG		The metric tare weight (in kgs) of the empty cylinder package. The empty cylinder package includes the cylinder, the valve, the carrying handle and the snap ring.

CO₂ cylinders are declared full when the weight of the CO₂ charge is equivalent to 68% of the weight of the total water  capacity of the cylinder. This is due to the expansion characteristics of the CO₂ charge and the dramatic affects the increase in temperature has on it. As the temperature increases the CO₂ charge greatly expands. In a cylinder, since the charge is limited to the capacity  of the cylinder, the expansion is measured as an increase in pressure.

Following is a description of the relationship between the pressure of the CO₂ charge in a 20 lb. CO₂ cylinder and the affects of exposure to increased temperature has on it.

• A 20 lb. CO₂ cylinder is filled with liquid CO₂ by weight. At the time of fill the temperature of the charge is extremely cold and the pressure is around 100 psi.
• When a fully charged 20 lb. CO₂ cylinder, 68% full by water capacity, warms up to room temperature (70 ^oF), the pressure inside the cylinder increases to 837 psi.
• When the same cylinder reaches 87.9 ^oF the  entire charge becomes a gas no matter what the pressure. A fully charged CO₂ cylinder at 87.9 ^oF will have an internal pressure of approximately 1100 psi.
• At 120 ^oF the same cylinder will have an internal pressure of nearly 2000 psi. This cylinder at  120 ^oF now has an internal pressure greater than the marked service pressure of the cylinder and is properly filled, not overfilled.
• At 155 ^oF the same cylinder  will reach a pressure of 3000 psi, a pressure great enough activate the safety venting the charge through the safety.

As you can see, when the temperature  of the fully charged cylinder increases, the pressure increases. A temperature of 155 ^oF, at  which the safety would actuate and vent the contents of the cylinder, is not that high  of a temperature. This temperature could easily be reached in many  different environments (i.e. in a shed or a vehicle on a hot day or in the kitchen of a restaurant, etc.).  Unexpected venting of a cylinder through its safety can be startling to personnel potentially  leading to accidents, property damaged, or personal injury. Coming into contact with the venting of the CO₂ charge of a cylinder can cause personal injury such as frostbite.

When using, handling, transporting, and storing a CO₂ cylinder, always be aware of the temperature to which the cylinder  will be exposed. This is not just the temperature the cylinder is exposed to at that point in time,  but also the maximum temperature that the cylinder will be exposed to at  any time in it’s service. Catalina Cylinders, along with the CGA, recommends that CO₂ cylinders not be used at temperatures exceeding 120 ^oF.

Overfilling a CO₂ cylinder, be it an attempt to get longer service out of one charge of a cylinder or be it accidental, can have unexpected and even catastrophic consequences due to the expansion characteristics of the CO₂ charge.

We at Catalina Cylinders have heard many times that it is not fair that a CO₂ cylinder is deemed full at only 68% of its water capacity, that there appears to be 32%  of its water capacity that is not being used, or wasted, and that this capacity not being used could be used for extended service life of  one CO₂ charge. This 32% is not spare, or wasted, capacity. Following are three situations that identify why this 32% of the total water capacity of a CO₂ cylinder is not spare, or wasted, capacity.

1. A 20# CO₂ cylinder with a full charge (68% of its water capacity)
   When a fully charged, 68% full by water capacity, 20# CO₂ cylinder warms up to room temperature (70⁰ F), the pressure inside the cylinder is 837psi. When the cylinder reaches 87.9⁰ F the entire charge becomes a gas no matter what the pressure. A fully charged CO₂ cylinder at 87.9⁰ F will have an internal pressure of approximately 1100psi. At 120⁰ F a fully charged CO₂ cylinder will have an internal pressure of nearly 2000psi,  this is greater than the designed service pressure of 1800psi of the cylinder. Remember that this cylinder at 120⁰ F has an internal pressure greater than  the marked service pressure of the cylinder and is properly filled, not overfilled. Also note that 120⁰ F is not an excess temperature  and can quite easily be reached in many different environments (i.e. in a shed or a vehicle on a hot day or in a kitchen).
2. A 20# CO₂ cylinder with a 5# overfill (85% of its water capacity)
   The following would occur if a 20# CO₂ cylinder were slightly overfilled with 25# of CO₂ charge to increase its service life between fills. When the cylinder and charge warm to room temperature the internal pressure of the cylinder  would be 1430psi. If the cylinder were warmed to 103⁰ F the cylinder would vent through the safety  device of the valve. This venting would most likely be unexpected since it would not be known when the cylinder would warm to 103⁰ F.  Unexpected venting through the safety device of a valve has caused property damage and personal injury.
3. A 20# CO₂ cylinder greatly overfilled (95% of its water capacity)
   A 20# CO₂ cylinder filled to 95% of it’s capacity, not quite liquid full would vent through its safety prior to the  cylinder reaching room temperature, 70⁰ F. If the safety disc has been altered and reinforced and would not actuate,  the cylinder would rupture between 85⁰ – 95⁰ F. Rupturing cylinders have caused severe property damage and serious personal injury, even loss of life.

Accidental overfilling or overfilling due to inaccurate  equipment (i.e. the scale being used in the filling process not being calibrated or not being able to measure in small enough units  of measure to accurately fill small cylinders) will have the same results as purposely overfilling a cylinder. The affects of accidental overfilling of a small CO₂ cylinder can have catastrophic affects as described below.

A 2.5# CO₂ cylinder filled accidentally with 1 extra pound of CO₂ will be filled to 95% of its capacity. As stated above, a cylinder filled to 95% of its water capacity would vent through  its safety device before the cylinder warms to room temperature.

In summary, never overfill a CO₂ cylinder, on purpose or accidentally. The affects of overfilling coupled with the affects of increasing temperature on the CO₂ charge, will greatly increase the probability that something catastrophic could happen to property or personnel. Do not take the risk, do not overfill a CO₂ cylinder.

Overfilling a CO₂ cylinder, be it an attempt to get longer service out of one charge of a cylinder or be it accidental,  can have unexpected and even catastrophic consequences due to the expansion characteristics of the CO₂ charge.

We at Catalina Cylinders have heard  many times that it is not fair that a CO₂ cylinder is deemed full at only 68%  of its water capacity, that there appears to be 32% of its water capacity that is not being used,  or wasted, and that this capacity not being used could be used for extended service life  of one CO₂ charge. This 32% is not spare, or wasted, capacity. Following are three  situations that identify why this 32% of the total water capacity of a CO₂ cylinder is not spare, or wasted, capacity.

1. A 20-ounce CO₂ paintball cylinder with a full charge (68% of its water capacity) When a fully charged, 68% full by water capacity, 20-ounce CO₂ cylinder warms up to room temperature (70 ^oF), the pressure  inside the cylinder is 837 psi. When the cylinder reaches 87.9 ^oF the entire  charge becomes a gas no matter what the pressure. A fully charged CO₂ cylinder at 87.9 ^oF will have an internal  pressure of approximately 1100 psi. At 120 ^oF a fully charged CO₂ cylinder will have an internal pressure of nearly 2000 psi, this is greater  than the designed service pressure of 1800 psi of the cylinder. Remember that this cylinder  at 120 ^oF has an internal pressure greater than the marked service pressure  of the cylinder and is properly filled, not overfilled. Also note that 120 ^oF is not an excess  temperature and can quite easily  be reached in many different environments (i.e. in a shed or a vehicle on a hot day or in a kitchen).
2. A 20-ounce CO₂ paintball cylinder with a 5-ounce overfill (85% of its water capacity)
   The following would occur if a 20-ounce CO₂ cylinder were slightly overfilled with 25 ounces of CO₂ charge to increase its service life between fills.  When the cylinder and charge warm to room temperature the internal pressure  of the cylinder would be 1430 psi. If the cylinder were warmed to 103 ^oF  the cylinder would vent through the safety device of the valve. This venting would most likely  be unexpected since it would not be known when the cylinder would warm to 103 ^oF.  Unexpected venting through the safety device of a valve has caused property damage and personal injury.
3. A 20-ounce CO₂ paintball cylinder greatly overfilled (95% of its water capacity)
   A 20-ounce CO₂ cylinder filled to 95% of it’s capacity,  not quite liquid full would vent through its safety prior to the cylinder reaching room temperature,  70 ^oF. If the safety disc has been altered and reinforced and would  not actuate, the cylinder would rupture between 85 ^o – 95 ^oF. Rupturing cylinders  have caused  severe property damage and serious personal injury, even loss of life.

Accidental overfilling or  overfilling due to inaccurate equipment (i.e. the scale being used in the filling process not being  calibrated or not being able to measure in small enough units of measure to accurately fill  small cylinders) will have the same results as purposely overfilling a cylinder. The affects of accidental overfilling of a small CO₂ cylinder can have catastrophic affects as described below.

A 7-ounce CO₂ paintball cylinder filled accidentally with 2.8 extra ounces of CO₂ will be filled to 95% of its capacity. As stated above, a cylinder  filled to 95% of its water capacity would vent through its safety device before the cylinder warms to room temperature.

In summary, never overfill a CO₂ cylinder, on purpose or accidentally. The affects  of overfilling coupled with the affects of increasing temperature on the CO₂ charge, will greatly increase the probability  that something catastrophic could happen to property or personnel. Do not take the risk, do not overfill a CO₂ cylinder.

Catalina Cylinders recommends
that trained personnel fill CO₂ cylinders. CGA pamphlets G-6; Carbon
Dioxide and G-6.3;  Carbon Dioxide Cylinder Filling and Handling
Procedures and 49CFR 173.304; Charging of Cylinders with  Liquefied
Compressed Gas be referenced, or included in, the training process and the  following
items be incorporated into any CO₂ cylinder filling procedure.

1. Perform a quick external inspection  of the cylinder and
   valve as noted in Catalina Cylinders’ technical support document, CO₂
   Cylinder Inspection at the Time of Each Fill.
2. Never fill a damaged cylinder, a cylinder  with a damaged
   valve, or a cylinder with a valve safety relief device that appears to be
   altered.
3. Never fill or “top off” a partially filled CO₂ cylinder.
4. Position the cylinder to be  emptied of its remaining contents.
   If the cylinder is not equipped with a dip tube the cylinder 
   should be inverted. Rotate the cylinder so the valve port is facing away from
   all personnel and equipment.
5. After moving or positioning the  cylinder for emptying,
   allow a few minutes for any residual CO₂ charge to settle before
   emptying the cylinder. Slowly open the valve, emptying any remaining charge 
   and other contents (i.e. moisture, contamination, corrosion, etc.) from the
   cylinder. Close the valve.
6. If any content other than the CO₂ charge, including any unusual
   odor, is discharged from the cylinder when emptying  the cylinder,
   the cylinder should not be filled and should be subjected to further inspection
   and followed by internal cleaning.
7. Place the cylinder on a calibrated scale.  The scale should
   be able to measure the weight of the cylinder to 3 significant 
   digits (i.e. XX.X lbs. or X.XX lbs. depending on the size of the cylinder).
8. Secure the connection (filling) hose to the valve.
9. Record the weight of the connected empty cylinder to 3 significant digits.
10. Add this weight  to the maximum allowable CO₂ charge weight (capacity)
    for this cylinder. Many cylinders are marked with thisCO₂ on the
    crown of the cylinder. This will be  the target fill weight, cylinlder wieght
    when fully charged,at the end of the fill.
11. Open the valve slowly and fill the cylinder slow  enough
    to accurately monitor the scale as to not exceed the target fill weight.
12. Stop the fill by closing the cylinder valve  when the cylinder
    on the scale has reached the target fill weight.
13. With the hose still connected, verify  the final weight
    is the same as the target fill weight.
14. If the cylinder has been overfilled, discharge the overfill immediately
    – do not wait.

Never overfill a CO₂ cylinder. Never fill a CO₂ cylinder
with a charge greater than the target fill weight marked on the crown of the cylinder.
Overfilling a CO₂ cylinder, even by a slight amount, can cause the
safety release device to actuate and discharge CO₂ unexpectedly. Unexpected
discharge of CO₂ gas through the safety relief device has been known
to cause accidents, sometimes leading to personnel injury or property damage.

Catalina Cylinders recommends that anyone handling CO₂ cylinders should be aware of the hazards associated with CO₂ and be trained in safe practices of handling CO₂ cylinders. All practices of handling CO₂ cylinders ought to include or reference information from CGA pamphlets G-6;  Carbon Dioxide and G-6.3; Carbon Dioxide Cylinder Filling and Handling Procedures.

Catalina Cylinders has compiled  the following list of items that should be included in any safe handling practice of CO₂ cylinders.

1. Only trained personnel should handle CO₂ cylinders. Trained personnel should be aware of the hazards associated with CO₂. CO₂ discharged from a cylinder is extremely cold and can cause injury if it comes into contact with personnel.
2. CO₂ cylinders should only be handled with care. Never drag or drop cylinders.
3. Never attempt to handle a leaking CO₂ cylinder.
4. CO₂ cylinder should never be handled in areas of extreme heat (125 ^oF or greater).
5. The valve should always be  closed when handling a cylinder.
6. If a cylinder is fitted with a valve cap,  always verify the cap is secure before handling.
7. If a cylinder is fitted with  a carrying handle, always verify the carrying handle is secure and not broken  before handling. Never handle a cylinder by a broken carrying handle.
8. Be aware that cylinders  that have been in service may have sharp edges from previous rough handling.  Visually inspect the cylinder for sharp edges prior to handling  the cylinder with your hands.
9. When lifting a cylinder, use  proper lifting techniques.
10. When handling a cylinder with  equipment, make sure the equipment does not scar or damage the cylinder or valve.
11. When using a cart to handle cylinders, always secure the cylinder to the cart.
12. After handling a cylinder, always  transport and/or store the cylinder in accordance with good safe transporting and/or storing practices.

Including the above items in all  practices for handling CO₂ cylinders should enhance the safety of all  personnel, equipment and property.

Catalina Cylinders recommends all CO₂ cylinders be given a quick external visual inspection prior to each fill and the items noted in Catalina Cylinders technical support document, Inspection of CO₂ Cylinders Prior to Each Fill, be included in this inspection.

All DOT-3AL marked CO₂ cylinders are to be inspected and hydrostatically re-tested every five years as required in CFR  Title 49 Part 180.205(c). Cylinders still with charge at the time the 5 year re-test is due, do not have to be re-tested  until the charge is used, but prior to the re-filling of the cylinders.

Visual inspection, at the time of hydrostatic re-testing,  must be performed by a DOT licensed re-test agency. Visual inspection  must be performed in accordance with CGA pamphlet C-6.1; Standards for Visual Inspection  of High Pressure Aluminum Compressed Gas Cylinders. Internal and external visual  inspection of a cylinder should be performed prior to hydrostatic re-testing.

Hydrostatic re-testing must be performed by  a DOT licensed re-test agency. Hydrostatic re-testing must be performed in accordance with  CGA Pamphlet C-1; Methods for Hydrostatic Testing of Compressed Gas Cylinders.  Once a cylinder has successfully passed all visual inspection and hydrostatic  re-test requirements, it is to be permanently marked with the re-test date, month and year,  and licensed re-test agency’s number in the proximity of the previous hydrostatic test date.  No cylinder is to be marked with the licensed re-test agency’s number until  the cylinder has passed all visual inspection and hydrostatic re-test requirements. No  cylinder is to be marked with a licensed re-test agency number by any other person or  agency other than the personnel of the licensed re-test agency.

DOT-3AL marked cylinders used in countries  other than the United States must be inspected and hydrostatically re-tested  in accordance with the rules, regulations, specifications and methods of that country.  If, in other countries, no such rules, regulation, specifications and methods  exist, Catalina Cylinders recommends that the DOT-3AL marked cylinders be visually inspected  in accordance with all applicable DOT specifications and CGA pamphlets.

The CGA pamphlets noted above, as well as all other CGA pamphlets,  can be attained from the CGA for a nominal fee. You can reach the CGA at:

Catalina Cylinders recommends that all CO₂ cylinders be subjected to a quick external inspection of the cylinder and  valve prior to each fill. This inspection may identify conditions of the cylinder and/or  valve that have decreased the integrity of the cylinder and possibly be an extremely dangerous  situation if the cylinder were filled. Following are items that Catalina Cylinders recommends  be included in the quick external inspection practice of any CO₂ cylinder prior to filling.

1. Inspect the crown markings on the cylinder. Verify that the cylinder is a CO₂ cylinder and that the cylinder has been  hydrostatically re-tested within the last 5 years of the most recent hydrostatic test date.
2. Inspect the cylinder for signs of damage and excessive wear  (i.e. dents, gouges, drag marks, etc.). Acceptable gouge limits for a 20 lb. CO₂ cylinder are listed in Catalina Cylinders’ Technical Support Document,  Calculation of an Acceptable Dig (Gouge) in a 20 lb. CO₂ Cylinder.
3. Inspect the cylinder for sign of  exposure to high heat or fire. Visible signs of exposure to high heat or fire include:
   • • Charring, blistering, or discoloration of the cylinder paint or labels,

    

   • • Distortion of the cylinder body,

    

   • • Melting of any components (i.e. the valve handwheel, the carrying handle, etc.) or,

    

   • • Activation of the valve pressure relief device.

    

    

   Any cylinder that shows visible signs of being  exposed to high heat or fire must not be filled, pulled from service, and subjected to a more thorough inspection.

4. Inspect the safety relief device of the valve.  Verify that the safety relief device has not been actuated or altered.  Do not fill a cylinder that has an actuated or altered safety relief device.
5. Inspect the valve. Verify that  the valve is the right type of valve for the cylinder. Verify the valve is seated completely  (tight) into the cylinder. Verify the handwheel and outlet threads of the valve are not  damaged. Slightly open “crack” the handwheel of the valve to check the  operation of the valve and to check cylinder for charge. Do not fill a cylinder that has  a damaged valve.
   The above noted items that Catalina Cylinders recommends to be  performed as a quick external inspection of a cylinder prior to filling can be supported  by any other means of inspection that you may feel is necessary to ensure that a cylinder is acceptable to fill.

If you have any questions about a cylinder’s  integrity, please call Catalina Cylinders and discuss your concerns before filling the cylinder.

Catalina Cylinders recommends that anyone storing CO₂ cylinders should be aware of the hazards associated with CO₂ and be trained in safe practices of storing CO₂ cylinders. All practices of storing CO₂ cylinders ought to include or reference information from CGA pamphlets G-6; Carbon Dioxide and G-6.3;  Carbon Dioxide Cylinder Filling and Handling Procedures. Catalina Cylinders has compiled  the following list of items that should be included in any safe storage practice of CO₂ cylinders.

1. 1. CO₂ cylinders should always be stored in a specified area. The storage area should:
      • Be well ventilated. CO₂ gas in small concentrations, as little as 15%, can cause unconsciousness in less than one minute.
      • Be selected away from the edge of  any elevated areas. Cylinders falling from elevated areas can cause damage to  the cylinder, valve or property or injury to personnel.
      • Be selected away from, or protected from,  areas of high traffic. Areas of high traffic only increase the chance of an accident occurring.
      • Be dry and free of a corrosive atmosphere.
      • Have adequate means to secure all  cylinders stored in the area. The means of securing should be sufficient to hold  the cylinders in place, yet not cause damage to the cylinders.
      • Be a continuously cool place. Do not store  cylinders adjacent to any source of heat, intermittent or continuous. Safety relief devices of CO₂ cylinders are designed to operate when the  pressure of the cylinder exceeds 2800 – 3000 psi (depending on the design of  the safety relief device). A properly charged CO₂ cylinder could vent through it’s safety  relief device at approximately 150 ^oF (65.6 ^oC). A slightly overfilled CO₂ cylinder could vent through its safety relief device when exposed to  a much lower temperature. The CGA recommends that CO₂ cylinders be stored in areas with a temperature less than 125 ^oF (51.7 ^oC).

1. Never store a charged CO₂ cylinder in a passenger vehicle or in the cab portion of any vehicle.
2. Empty CO₂ cylinders should be stored with the valve tightly closed.
3. Cylinders can be stored standing on  their base or lying on their side. Catalina Cylinders recommends that the cylinders  be stored as designed, standing on their flat base.
4. Cylinders should not be stored where they might become part of an electrical circuit.
5. Cylinders, which have been manufactured  to accommodate a valve protective carrying handle or a protective cap,  should be stored with these accessories in place.

Including the above items in all practices for storing CO₂ cylinders should enhance the safety of all personnel, equipment and property.

Catalina Cylinders recommends that anyone transporting CO₂ cylinders should be aware of the hazards associated with CO₂ and be trained in safe practices of transporting CO₂ cylinders. All practices of transporting CO₂ cylinders must be in compliance with and ought to include or reference information from 49 CFR 173.302; General Requirements  For Shipment of Compressed Gases in Cylinders and Spherical Pressure Vessels,  49 CFR 173.304; Charging of Cylinders With Liquefied Compressed Gas, and  CGA pamphlet G-6.3; Carbon Dioxide Cylinder Filling and Handling Procedures. Catalina Cylinders  has compiled the following list of items that should be included in all safe practices of transporting CO₂ cylinders.

1. Never transport a filled CO₂ cylinder in a passenger vehicle.
2. Cylinders should never be transported in an  enclosed vehicle unless the driver is separated from the cargo by a gas tight barrier.
3. Cylinders should be transported in a  continuously cool place. Do not transport cylinders adjacent to any source of heat,  intermittent or continuous. Safety relief devices of CO₂ cylinders are designed to  operate when the pressure of the cylinder exceeds 2800 – 3000 psi (depending on the  design of the safety relief device). A properly charged CO₂ cylinder could vent through its safety  relief device at approximately 150 ^oF (65.6 ^oC). A slightly overfilled CO₂ cylinder could vent through its safety relief  device when exposed to a much lower temperature. The CGA recommends that CO₂ cylinders be stored in areas with a temperature less than 125 ^oF (51.7 ^oC).
4. Do not transport a leaking cylinder.
5. Damaged cylinders should only be transported without fill and marked “DAMAGED”.
6. Empty CO₂ cylinders should be transported with their valves tightly closed.
7. Cylinders, which have been manufactured  to accommodate a carrying handle or a protective cap, should be transported  with these accessories in place. Do not transport cylinders with broken carrying handles.
8. Cylinders can be transported standing  on their base or lying on their side. Catalina Cylinders recommends that the cylinders  be transported as designed, standing on their flat base. The CGA recommends  that cylinders that are shipped never be stacked on top of each other.
9. All cylinders, after being loaded for transit,  when in transit, and when waiting for unloading after transit should be  secured by adequate means to protect the cylinders. The means of securing should be  sufficient to hold the cylinders in place, yet not cause damage to the cylinders.
10. If a cylinder is determined to be leaking or venting CO₂ while in transit:
    • Immediately pull the vehicle over  to the side of the road. Do not try to continue driving, or remain in, the vehicle  while the cylinder is leaking or venting. Inhalation of as little as 3% CO₂ gas can cause uncomfortable physiological effects. Inhalations of large amounts of CO₂ gas, 10% and above, can cause unconsciousness (in less than 1 minute) and possibly death.
    • Do not try to stop the cylinder from leaking or venting. Leaking or venting CO₂ gas can cause frostbite.
    • Do not try removing a leaking or venting cylinder from a vehicle.

Including the above items in all practices for transporting CO₂ cylinders should enhance the safety of all personnel, equipment and property.

Catalina Cylinders recommends that anyone valving CO₂ cylinders should be aware of the hazards associated with CO₂ and be trained in safe practices of valving CO₂ cylinders. Catalina Cylinders has compiled the following  list of items that should be included in all safe practices for the valving CO₂ cylinders.

Valve Removal

1. Verify the cylinder is free of  charge and not under pressure before attempting to remove the valve.
2. Only discharge the remaining charge of a CO₂ cylinder in a well ventilated area.
3. Position the cylinder with outlet port  of the valve facing away from all personnel and/or equipment.
4. Slightly (“crack”) open the handwheel  of the valve discharging or releasing the residual CO₂ charge. Leave the  handwheel of the valve open throughout the valve removal process.
5. Fitting a wrench snugly to the valve body,  use force turning the wrench counter clockwise to loosen the valve.
6. If the valve cannot be loosened, stop,  remove the wrench and apply a small amount of penetrating release agent at the  junction of the valve and cylinder and allow time, 5 – 15 minutes, for the release agent to penetrate the junction.
7. Again attempt to loosen the valve. It may take  some time to work the valve free from the cylinder. If a valve is really stuck  and a release agent is used, you may have to stop periodically in the removal process and  reapply the release agent and allow time for the newly applied release agent to work.

Valve Insertion

• Verify that the cylinder was manufactured for CO₂ service.
• Verify the valve is a CGA recommended CO₂ valve.
• Verify that the safety device is the  correct safety device, is rated at the test pressure of the cylinder, and has not been actuated or altered (tampered with).
  • Never tamper with the safety device.  If the safety device appears to be tampered with, do not use the valve.
  • Never replace the safety device of a valve on a cylinder that is charged.
  • Catalina Cylinders recommends when  replacing a safety device replace the whole safety device assembly.
  • If a safety device has been actuated  and the cylinder has vented, then the cylinder may have been overfilled or exposed to high heat.

• Inspect the inlet and outlet threads of the  valve and the threads and o-ring gland of the cylinder for damage. If either the valve  or cylinder has damage to the threads or the o-ring gland area, do not insert the valve into the cylinder.
• Inspect the cylinder threads and the cylinder  internally verifying that the cylinder is free of all contaminants (i.e. release agents,  moisture, soils, corrosion, etc.). Do not proceed if you feel the cylinder  may be contaminated. Reference Catalina Cylinders Technical Support Document,  Cylinder Cleaning, for common methods of cleaning a cylinder.
• Catalina Cylinders recommends the  insertion of a new buna-N o-ring, with a hardness of 90 shore, every time the valve  of a cylinder is removed and re-installed. Verify that the new o-ring  is free of all damage. Following are the buna-N o-ring sizes for the different inlet thread sizes of CGA valves.
  

  Thread Designation	Valve Designation	Buna-N O-ring Size
  .625 – 18 UNF	CGA 323	206
  .750 – 16 UNF	CGA 320	210
  1.125 – 12 UNF	CGA 320	216

• Catalina Cylinders has found it easiest  to place the o-ring on the valve and then insert the valve into the cylinder tightening  the valve hand tight. Placing the o-ring in the o-ring gland of the cylinder and  then inserting the valve is known to have damaged the o-ring in some instances.
• Final tightening of the valve should be done  with a calibrated torque wrench to the recommended torque values noted as follows:
  

  Thread	Catalina Cylinders	Catalina Cylinders
  Designation	Recommended Torque	Maximum Torque
  .625 – 18 UNF	40 lbf-ft	50 lbf-ft
  .750 – 16 UNF	40 lbf-ft	50 lbf-ft
  1.125 – 12 UNF	40 lbf-ft	50 lbf-ft

• Close the valve with no more than 1 lbf-ft torque.