Yikes !!! Green Stripes!!!

Well by now you all should be aware of certain 2216 PSI cylinders that are identified with a large black number and a green stripe around the bottom of the bottle and green markings on or around the labeling of the bottle. The purpose of this identification is to assure these bottles are inspected annually by a DOT certified technician.

SCOTT Aviation sent out two Safety Notices. The first notice was dated 11-3-99 and second notice was dated 2-7-00. These notices alerted users of 12 cylinders that ruptured while in the process of being refilled. Of the 12, six were of the SCBA type we use. In particular, these cylinders have the DOT markings of 3AL2216, 3A EL6498-2216, E7235, and EL6498-2216 and were manufactured prior to 1988. These bottles were either all aluminum or composite aluminum wrapped with fiberglass. All cylinders were manufactured by Luxfer, although some will only show “SCOTT” stamped on the dome.

The notices recommended certain procedures be followed to assure these cylinders are safe to use. All the procedures have been done for now. These procedures were:

• Inventory and identify cylinders.

• Label cylinders.

• Have cylinders inspected by Certified DOT Technician on an annual basis. If hydrostatic test date is less than one year old, no need to conduct annual visual inspection.

• Confirm testing facility is Certified by DOT to conduct such inspections.

• Set up internal controls to assure cylinders will be inspected on an annual basis.

It should be noted facts were discovered about the most recent incident involving a rupturing cylinder. The incident occurred on the May 2, 1999 in Summerfield, NC. A cylinder was being refilled while in a fully enclosed filling station. No one was injured, but the filling station sustained considerable damage. It was discovered in subsequent analysis, there were “cracks in the neck region of the ruptured cylinder” that “were more than eight years old.” Further investigation revealed the cylinder had been leaking prior to rupture.

Ruptures were also attributed to “fast-filling”. Cylinders are to be filled at a rate not to exceed 600 PSI per minute. Our Service 341 fills at a rate of 500 PSI per minute. Since our cascade systems does not provide for such governing capabilities, all filling of cylinders has been suspended until further notice. Chief Kelley is looking into alternatives for refilling cylinders.

In light of the recent Safety Alerts issued by SCOTT Aviation on some faulty 2216 PSI cylinders, our department did an extensive review of its cylinder inventory to determine the extent of our potential problem. We screened 43 cylinders and 33 “green-striped” bottles. All were inspected by an outside testing company. Only one failed and was replaced by SCOTT under warranty.

The problem continued with yet another Safety Alert from SCOTT on limiting the refilling process to a controlled PSI which can only be done by Service 341. NIOSH also recommended [OSHA usually follows NIOSH] these cylinders and all cylinders should be filled within an enclosed filling station to protect the personnel from a potential cylinder failure [explosion].

With these facts in hand, Chief Kelley has decided to take advantage of a conversion process being offered by SCOTT. They offer a change over from a 2.2 system to a 4.5 system with the purchase of a new 4.5 carbonized composite bottle at a reduced price. For every bottle purchased, a 2.2 SCBA will be changed over to a 4.5 PAK. We have 26 2.2 PAKs to convert. This will solve the 2.2 cylinder issue. Plans for this to start will be after July 1, 2000.

The enclosed filling station for both Service 341 and fire stations are in the planning stages. The Chief and the Safety Committee are looking into what systems are available and the expense involved.

Our department has an aggressive inspection process, unlike other departments. We inspect our SCBA units weekly. We hydro-statically test all our air-cylinders and cascade systems. Our inspections are documented, as well as maintenance on all SCBA units and cylinders. These procedures are working because all of you are doing your jobs! Keep up the good work. We can never be too safe; our lives depend upon it.

Remember, once the “Green Striped” bottles are emptied, they are to be returned to the SCBA Workshop for handling. Please monitor ALL bottles [2.2 or 4.5] for any air loss. During your weekly inspections of cylinders, make sure they are clean and free of any caustic materials and damage to fiberglass or Kevlar or carbon fiber wrap. If you have any questions on the SCBA, please call me. Be Safe.