Protecting People and the EnvironmentUNITED STATES NUCLEAR REGULATORY COMMISSION
SSINS No.: 6835
IN 84-34
UNITED STATES
NUCLEAR REGULATORY COMMISSION
OFFICE OF INSPECTION AND ENFORCEMENT
WASHINGTON, D.C. 20555
April 23, 1984
Information Notice No. 84-34: RESPIRATOR USER WARNING: DEFECTIVE SELF-
CONTAINED BREATHING APPARATUS AIR CYLINDERS
Addressees:
All nuclear power reactor facilities holding an operating license (OL)
or construction permit (CP), research and test reactor facilities, fuel
cycle licensees, and Priority 1 material licensees.
Purpose:
This information notice is intended to alert licensees of a serious defect
in self-contained breathing apparatus (SCBA) hoop-wrapped aluminum air
cylinders rated at 4,500 psi, manufactured under the Department of
Transportation (DOT) Exemption DOT-E 7235. During refilling operations at
a fire department, one cylinder ruptured and injured one person. The
National Institute of Occupational Safety and Health (NIOSH) has issued
a Respiratory Users Notice, in concert with a DOT Federal Register
Notice limiting filling/operating pressure of the affected cylinders to
4,000 psi until further notice.
NRC regulations require that only NIOSH-certified respiratory equipment
shall be used as emergency devices. Licensees are expected to review the
information for applicability to their facilities respiratory protection
program and take actions, as required, to maintain NIOSH and DOT
certifications for affected equipment and to minimize the probability of
catastrophic cylinder failure. Further NRC action may occur after the
DOT/NIOSH evaluations are completed and reviewed by the staff. No written
response to this notice is required.
Description of Circumstances
The NRC recently has learned of a serious defect in certain SCBA air
cylinders that caused a rupture of a high-pressure (4,500 psi) air cylinder
(rated for 30-minute service) manufactured by Luxfer Limited in 1978 for
Scott Aviation. On February 4, 1984, a Scott 4.5 cylinder ruptured at the
neck area during a routine refilling at a New York City fire station. The
air charging hose that was still attached to the ejected cylinder
material, struck the attending fireman. Although not seriously injured,
the fireman was severely bruised in the shoulder area, transported to a
nearby hospital, and treated and released the same day. The fireman was
fortunate that a flying metal fragment did not hit him. This cylinder was
not subject to an earlier product recall discussed below.
.
IN 84-34
April 23, 1984
Page 2 of 3
On October 11, 1983, the NRC reported in IE Information Notice
83-68, "Respirator User Warning: Defective Self-Contained Breathing
Apparatus Air Cylinders," that several identical Luxfer cylinders
manufactured since mid 1982 for Scott and other vendors, had developed
cracks around the neck area. Two of these cylinders had ruptured. A product
recall directed at a specific manufacturing batch of these hoop-wrapped
cylinders had been initiated at that time.
Discussion:
In response to the recent New York City event and other evidence of
cylinder cracking, the DOT Office of Hazardous Material Regulation has
amended the exemption to limit the filling pressure for all high pressure
(4,500 psi) composite hoop-wrapped cylinders manufactured under Exemption
DOT-E 7235. The Federal Register Notice (49 FR 39, p. 7182--see Attachment
1), issued by DOT February 27, 1984, states that
Persons owning, using, or otherwise having control over cylinders marked
DOT-E 7235-4500, must limit the filling pressure to 4,000 psi, and reduce
to 4,000 psi the pressure in cylinders already charged. (emphasis added)
NIOSH issued a Respirator User Notice on February 29, 1984 (see Attachment
2), which establishes interim actions to be taken by all users in
order to maintain a revised NIOSH certification for the units effective
until further DOT action, at which time the certification may be
reaffirmed, revised, or revoked. Under this temporarily revised
certification (unit rated as a "not less than 25-minute" device), each
user should
1. Refill and operate all Luxfer 4,500 psi, 30-minute, hoop-wrapped
aluminum cylinders at the reduced pressure of 4,000 psi.
2. Follow the instructions provided by Luxfer for immediate removal
from service and physical examination of affected cylinders manufactured
before May 1981.
General recommendations (p. 3 of Attachment 2), issued by NIOSH, offer
users sound advice for further reducing the probability of cylinder
catastrophic failure and, thereby, increasing worker safety.
The interim actions, established by DOT and NIOSH, must be carefully
observed to continue the NIOSH certification of the unit as a "not less than
25-minute" device. However, licensees also are reminded that Section III.H
of 10 CFR 50, Appendix R (Fire Protection Program for Nuclear Power
Facilities Operating Prior to January 1, 1979), requires a rated operating
air supply of at least 30-minutes for all SCBA provided for use by fire
brigade, damage control parties, and control room personnel. If any
affected cylinders are fulfilling 10 CFR 50, Appendix R, requirements,
then appropriate compensatory air supplies must be provided. Licensees may
choose to request temporary exemption from the 30-minute-rated supply
requirement in 10 CFR 50 by contacting their appropriate NRC licensing
office.
.
IN 84-34
April 23, 1984
Page 3 of 3
To provide further information, copies of Scott Aviation and Survivair
warning letters to their customers are attached (Attachments 3 and 4). If
you have any questions concerning this problem, please call the number
listed on the appropriate customer warning letter or contact the Regional
Administrator of the appropriate NRC Regional Office or this office.
Edward L. Jordan, Director
Division of Emergency Preparedness
and Engineering Response
Office of Inspection and Enforcement
Technical Contacts: J. E. Wigginton, IE
(301) 492-4967
L. Hendricks, RES
(301) 443-7675
Attachments:
1. DOT Federal Register Notice
2. NIOSH Respirator Users Notice
3. Scott Aviation Letter
4. Survivair Letter
5. List of Recently Issued IE Information Notices
.
Attachment 2
IN 84-34
April 23, 1984
DEPARTMENT OF HEALTH & HUMAN SERVICES
Centers for Disease Control
National Institute for Occupational
Safety and Health--ALOSH
944 Chestnut Ridge Road
Morgantown, WV 26505
February 29, 1984
RESPIRATOR USERS NOTICE
Reduced Service Pressure and Physical Examination of
4500 psi Hoop-wrapped Aluminum Cylinders Manufactured by
Luxfer USA Ltd., 1995 3rd Street, Riverside, CA 92507.
The National Institute for Occupational Safety and Health (NIOSH) has
been informed of two recent actions which affect the continued safe use of
Luxfer 4500 psi hoop-wrapped aluminum cylinders and the certified status
of self contained breathing apparatus incorporating them in their
assemblies.
(1) The Department of Transportation (DOT) has announced in the
Federal Register that in order to accomplish a reduction in the sustained
stress in 4500 psi hoop-wrapped aluminum cylinders manufactured by
Luxfer under Exemption DOT-E 7235, the maximum cylinder charging pressure
must be reduced from 4500 to 4000 psi, effective February 28, 1984. This
restriction does not apply to 4500 psi fully-wrapped aluminum cylinders.
(2) Luxfer USA Ltd. has determined that some 4500 psi/DOT-E 7235 hoop-
wrapped aluminum cylinders manufactured prior to May, 1981, may rupture
or develop longitudinal cracks in the threaded section of the cylinder
neck. All such cylinders with manufacturing dates before May, 1981,
should be immediately examined in accordance with Luxfer's instructions
which may be obtained from the self-contained breathing apparatus
manufacturer. Cylinders manufactured after May, 1981, should be examined
during the normal hydrostatic test.
The following self-contained breathing apparatus certified by the Mine
Safety and Health Administration (MSHA) and NIOSH, incorporate 4500 psi/DOT-
E 7235 hoop-wrapped aluminum cylinders manufactured by Luxfer:
Manufacturer Approval No. Model No.
AGA TC-13F-133 4530
Clifton Precision TC-13F-136 7010421-1, -2, -3, -4
(Bendix)
MSA TC-13F-142 473640, 473645
National Draeger TC-13F-119 4059-200, -201, -202, -203, -204, -205,
-206 Siebe Gorman TC-13F-99 014422.16
Scott TC-13F-73 900450-00, -01, -30,-31
TC-13F-76 900455-00, -01, -10, -11 -20,-21,-30,
-31, -40, -41, -50, -51
USD TC-13F-82 9045-20, -22; 9845-20, -22
TC-13F-108 9840-00, -01, -02, -03,--20,-21, -22, -23
9841-21, -23
.
Attachment 2
IN 84-34
April 23, 1984
Page 2 of 3
Reduction of Service Pressure
Users of self-contained breathing apparatus incorporating any Luxfer
4500 psi/DOT-E 7235 hoop-wrapped aluminum cylinders (including those
manufactured before and after May, 1981) should immediately reduce the
pressure in such cylinders from 4500 to 4000 psi. Pressure reduction may
be safely accomplished by attaching the cylinder to a self-contained
breathing apparatus and following the breathing apparatus
manufacturer's instructions for depressurization until the cylinder
pressure has reached 4000 psi. DO NOT OPEN THE VALVE OF ANY PRESSURIZED
CYLINDER THAT IS NOT ATTACHED TO A SELF-CONTAINED BREATHING APPARATUS OR
OTHER DEVICE THAT WILL SAFELY CONTAIN THE RELEASED PRESSURE. When
depleted Luxfer 4500 psi/DOT-E 7235 hoop-wrapped aluminum cylinders are
recharged after use, the maximum pressure of 4000 psi must not be exceeded.
Status of MSHA/NIOSH Certifications
The reduction in maximum service pressure from 4500 to 4000 psi affects
the MSHA/NIOSH certification of the self-contained breathing apparatus
to the extent that they will no longer meet the service time requirements
of Title 30 Code of Federal Regulations Part 11 for a 30-minute
duration apparatus. Therefore it is necessary for NIOSH to temporarily
revise the certifications for these apparatus to continue their certified
status. After consideration of the several factors involved in the maximum
pressure reductions, NIOSH has decided to temporarily reduce the
certification rated service time for each of the apparatus listed above,
from 30 minutes to not less than 25 minutes. The revised certifications
will be effective until further action is taken by DOT, at which time they
will be further revised, canceled, or made official by publication in
the Federal Register. This temporary change does not otherwise affect the
certifications of these apparatus.
Respirator users should immediately take the reduced service time
into consideration in their continued use of the apparatus. NIOSH will
also temporarily modify the certification to the extent of continuing to
require the remaining service time indicator to continue to function within
the range of 20 to 25 percent of the original 30-minute service time rating.
Therefore, users will observe no change in the amount of service time
remaining after initial activation of the remaining service time indicator,
and will have the usual service time available for escape from an
atmosphere immediately dangerous to life or health.
Physical Examination of Cylinders
Users of self-contained breathing apparatus incorporating any Luxfer
4500 psi/DOT-E 7235 hoop-wrapped aluminum cylinders should immediately
observe the manufacturing date of each such cylinder. This date is either
stamped on the cylinder neck or is printed on a label which appears on
the side of the cylinder under the outer filament wrapping. Hoop-
wrapped cylinders may be identified by lack of filament winding on the
bottom and neck areas. Luxfer recommends that each of their 4500
psi/DOT-E 7235 hoop-wrapped aluminum cylinders manufactured before May,
1981, be removed from service, be completely depressurized, devalved,
and examined according to Luxfer's instructions which may be obtained
from the self-contained breathing apparatus manufacturer. Contact the
respirator manufacturer or distributor if you have not received the
necessary instructions. Cylinders manufactured after May, 1981, should be
examined during the normal hydrostatic test.
.
Attachment 3
IN 84-34
April 23, 1984
Page 1 of 1
February 24, 1984
Dear Customer,
Luxfer USA Limited is the manufacturer of the 30-minute duration hoop-
wrapped high pressure cylinder, Scott P/N 802239-01, which is used in
Air-Pak 4.5 self-contained breathing apparatus. A copy of their letter
to us dated February 23, 1984 regarding this cylinder is attached.
In view of the situation outlined in the Luxfer letter, it is imperative
that you immediately follow the instructions contained in that letter
including:
- To reduce the service pressure on all 30-minute 4500 psi hoop-
wrapped cylinders to 4000 psi immediately and to take whatever steps are
necessary to assure future fillings will not exceed 4000 psi.
- To visually inspect all 30-minute 4500 psi hoop-wrapped cylinders as soon
as possible after receipt of Luxfer's recommended inspection procedure.
NOTE: These recommended actions are limited to the one cylinder, the 30-
minute hoop-wrapped 4500 psi cylinder, Scott P/N 802239-01, used in Scott's
4.5 Air Paks. If you have any questions, please contact Mr. Dennis Browner
at (716) 683-5100 - Ext. 314.
Be assured of our continuing interest in safety and in your full
satisfaction with Scott Aviation and our products. We will keep you
informed on this matter.
Cordially,
Lincoln C. Bailey
Vice President
Sales & Marketing
Health/Safety Products
.
Attachment 4
IN 84- 34
April 23, 1984
Page 1 of 2
February 29, 1984
URGENT SAFETY NOTICE
Dear Survivair Distributor:
We have been notified by Luxfer and NIOSH of two (2) recent
accidents involving Scott 4500 psi hoop wrapped aluminum cylinders
manufactured by Luxfer. Whereas no Survivair cylinders have been involved
in any accident, Luxfer has determined that some 4500 psi DOT E7235
hoop wrapped aluminum cylinders may rupture or develop longitudinal cracks
in the threaded section of the cylinder neck. And even though the threaded
section of the Survivair cylinders are significantly different from the
Scott cylinders that have been involved in these accidents, you are urged
at the direction of the Department of Transportation, NIOSH, Luxfer and
Survivair to immediately reduce the service pressure of all Survivair
hoop wrapped cylinders in your possession bearing DOT E7235 on the
cylinder neck from 4500 psi to 4000 psi. You are also urged to contact all
your customers of these cylinders and likewise advise them to immediately
reduce the service pressure to 4000 psi.
We have been informed by NIOSH that this reduction in service pressure
will not void NIOSH certification. However, users should take the reduced
service time into consideration in their continued use of the apparatus. OSHA
has also informed NIOSH that it will permit use of apparatus with a not
less than 25 minute service time rating until further resolution of the
problem.
Please advise your customers that this reduction in service pressure to 4000
psi will reduce the service time of the Mark I and Mark 2 high pressure
units from 30 minutes to approximately 26 minutes.
This notice does not affect or request any action on any other
Survivair cylinders other than those bearing DOT E7235. These cylinders are
only used in Survivair's Mark I (since 1978) and Mark 2 High Pressure, 30
minute units. (since 1983).
.
Attachment 4
IN 84-34
April 23, 1984
Page 2 of 2
A more detailed letter of explanation to follow. Your immediate action
and follow up in bringing this matter to the attention of your customers or
known users of these cylinders is greatly appreciated. Failure to do
so may potentially result in serious bodily injury, death, and/or property
damage.
Should you need any further information on this matter please call
the Survivair Marketing Department at 714/540-8010.
Sincerely,
Michael M. Chapman
Vice President, Marketing
