USE OF

RESIDUAL PRESSURE VALVES

Doc 64/16
Revision of Doc 64/11

EUROPEAN INDUSTRIAL GASES ASSOCIATION AISBL

AVENUE DES ARTS 3-5 • B – 1210 BRUSSELS

Tel: +32 2 217 70 98 • Fax: +32 2 219 85 14
E-mail: info@eiga.eu • Internet: www.eiga.eu
 Doc 64/16

USE OF RESIDUAL
PRESSURE VALVES

As part of a programme of harmonization of industry standards, the European Industrial Gases

Association (EIGA) publication, EIGA Doc 64, Use of residual pressure valves, has been used
as the basis of an internationally harmonized gas association’s publication on this subject.

This publication is intended as an international harmonized publication for the worldwide use
and application by all members of Asia Industrial Gases Association (AIGA), Compressed Gas
Association (CGA), European Industrial Gases Association, EIGA, and Japan Industrial and
Medical Gases Association (JIMGA). Regional editions have the same technical content as the
EIGA edition, however, there are editorial changes primarily in formatting, units used and
spelling. Regional regulatory requirements are those that apply to Europe.

Disclaimer
All technical publications of EIGA or under EIGA's name, including Codes of practice, Safety procedures and any other technical
information contained in such publications were obtained from sources believed to be reliable and are based on technical
information and experience currently available from members of EIGA and others at the date of their issuance.

While EIGA recommends reference to or use of its publications by its members, such reference to or use of EIGA's publications by
its members or third parties are purely voluntary and not binding.

Therefore, EIGA or its members make no guarantee of the results and assume no liability or responsibility in connection with the
reference to or use of information or suggestions contained in EIGA's publications.

EIGA has no control whatsoever as regards, performance or non performance, misinterpretation, proper or improper use of any
information or suggestions contained in EIGA's publications by any person or entity (including EIGA members) and EIGA expressly
disclaims any liability in connection thereto.

EIGA's publications are subject to periodic review and users are cautioned to obtain the latest edition.

 EIGA 2016 - EIGA grants permission to reproduce this publication provided the Association is acknowledged as the source

EUROPEAN INDUSTRIAL GASES ASSOCIATION AISBL

Avenue des Arts 3-5 B 1210 Brussels Tel +32 2 217 70 98 Fax +32 2 219 85 14
E-mail: info@eiga.eu Internet: www.eiga.eu
EIGA DOC 64/16

Table of Contents
1 Introduction ...................................................................................................................................... 1
2 Scope and purpose .......................................................................................................................... 1
2.1 Scope ........................................................................................................................................ 1
2.2 Purpose .................................................................................................................................... 1
3 Definitions ........................................................................................................................................ 1
3.1 Publication terminology ............................................................................................................ 1
3.2 Technical definitions ................................................................................................................. 2
4 Benefits of residual pressure valves ................................................................................................ 2
5 Applications ...................................................................................................................................... 3
6 Use of residual pressure valves—Filling facilities ............................................................................ 3
6.1 Prefill inspection recommendations and requirements............................................................. 3
6.2 Fill connectors ........................................................................................................................... 4
6.3 Installing residual pressure valves into cylinders ..................................................................... 5
6.4 Devalving cylinders equipped with residual pressure valves ................................................... 6
7 References ....................................................................................................................................... 6

Figure 1—Example of a fixed pin adapter ............................................................................................... 4

Figure 2—Example of a retractable pin design ....................................................................................... 5

Amendments to 64/11

Section Change
Rewrite following adoption as a harmonised publication
EIGA DOC 64/16

1 Introduction

Cylinder valves that retain a residual positive pressure in a gas cylinder and some types of devices
that prevent backflow of fluid by means of a non-return device, commonly referred to as residual
pressure valves (RPV), have been available for many years. Important benefits of RPVs include
preventing moisture ingress and contamination, which reduce the potential for internal cylinder
corrosion. Additional benefits include productivity improvements in the cylinder fill operation, avoiding
internal cylinder contamination that could create hazardous situations, and reducing cylinder
maintenance.

In the past, industry relied on users not to allow backflow into cylinders. Fillers typically relied on prefill
inspection procedures to identify potentially contaminated cylinders returned from customers. Despite
these measures, incidents caused by backflow of contaminants into cylinders have occurred, which
highlight the potential benefit from usage of RPVs.

The use of RPVs generally requires a special fill connector for filling, evacuation, or both. The
dimensions of the fill connector need to match certain critical dimensions of the valve outlet.

2 Scope and purpose

2.1 Scope

This publication is intended for use by the compressed gas industry and provides guidelines for the
use of RPVs. This publication does not describe any design qualification tests of RPVs.

2.2 Purpose

The purpose of this publication is to give guidance on the selection, operation, maintenance, and
installation of these valves, so common practices are established across the gas industry and these
valves are beneficial to both the end user and filler of gas cylinders.

3 Definitions

For the purpose of this publication, the following definitions apply.

3.1 Publication terminology

3.1.1 Shall

Indicates that the procedure is mandatory. It is used wherever the criterion for conformance to specific
recommendations allows no deviation.

3.1.2 Should

Indicates that a procedure is recommended.

3.1.3 May

Indicates that the procedure is optional.

3.1.4 Will

Is used only to indicate the future, not a degree of requirement.

3.1.5 Can

Indicates a possibility or ability.

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EIGA DOC 64/16

3.2 Technical definitions

3.2.1 Residual pressure valve types

There are two types of RPVs; Type 1 and Type 2. Use of either Type 1 or Type 2 is dependent upon
operational and gas quality requirements. Both types contain a residual pressure device to retain a
positive pressure in the cylinder.

NOTE Some cylinder valves with integrated pressure regulators (VIPRs) can have similar positive pressure
and non-return functionality as RPVs.

3.2.1.1 Type 1

RPV that retains a positive pressure in the cylinder greater than the pressure downstream of the valve
outlet and also incorporates a non-return feature to prevent backflow into the cylinder from a higher
pressure on the valve outlet.

NOTE Cylinders with Type 1 RPVs cannot be filled or evacuated unless the RPV is deactivated or a special fill
connector is used to overcome the non-return feature.

3.2.1.2 Type 2

RPV that retains a positive pressure in the cylinder greater than atmospheric pressure but will not
prevent backflow into the cylinder if the pressure on the valve outlet is high enough to overcome the
RPV mechanism and the residual pressure in the cylinder.

NOTE Cylinders with Type 2 RPVs can be filled with a conventional fill connector but cannot be evacuated
unless the RPV is deactivated or a special fill connector is used.

4 Benefits of residual pressure valves

RPVs provide several benefits over conventional valves. Where there is a possibility of backflow, the
Type 1 with a non-return feature is more useful to ensure gas quality and cylinder internal condition
are not compromised. These benefits include:

• Maintaining positive pressure—A RPV will maintain positive pressure and prevent atmospheric
contamination if the valve is left open;

• Improved filling productivity—Depending on the gas purity required, the venting and evacuation
stages during the fill process may be eliminated allowing for the top-fill of cylinders;

NOTE Some regulations require venting and evacuation for certain products prior to filling regardless of the
type of valve installed.

• Extended service life of the cylinder—The lifetime expectancy of a cylinder is extended by

reducing the exposure of the cylinder internal surfaces to the atmosphere (moisture ingress),
which can lead to corrosion;

• Prevention of contaminants entering the cylinder—Type 1 RPVs can prevent the ingress of
contaminants for example sea water, toxics, and flammable materials such as solvents, oils,
gases, etc., which can lead to consequences on refilling or subsequent customer use. Type 1
RPVs are more useful in preventing backflow contamination;

• Potential for reduced risk of cylinder failure—Moisture ingress into the cylinder can cause
corrosion and stress corrosion cracking (SCC), which can lead to cylinder failure through leakage
or burst. The likelihood of moisture ingress can be significantly reduced through the use of RPVs;
and

• Potential for extended requalification period—As of 2015, the European Agreement concerning
the International Carriage of Dangerous Goods by Road (ADR) has a provision for a steel cylinder

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EIGA DOC 64/16

requalification period of 15 years for certain gases provided the cylinder has been equipped with a
1
RPV Type 1 throughout the retest interval [1].

NOTE At the time of publication, this only applies to the signatories of the ADR [1].

5 Applications

RPVs should be considered for the following:

• Applications where there is the possibility of internal corrosion due to the ingress of a fluid. For
example, sea water and moisture. This would benefit carbon steel cylinders used in marine
service;

• Applications where the cylinder is used in a service where the possibility of backflow
contamination from the end users process can create hazardous conditions for the end user or fill
plant operator. Examples include beverage dispensing, industrial nitrogen used in agricultural
applications to pressurize toxic chemicals, nitrogen used in oil and gas industries for inerting and
blanketing applications.

• Applications where gas purity is important such as high purity argon, helium, and medical or food
gas products; and

• Gases and gas mixtures such as those containing carbon monoxide in steel cylinders that are
susceptible to SCC.

NOTE RPVs are not adequate as the only safeguard to prevent SCC (see EIGA Doc 95, Avoidance of Failure
of Carbon Monoxide and of Carbon Monoxide/Carbon Dioxide Mixtures Cylinders [2]).

6 Use of residual pressure valves—Filling facilities

6.1 Prefill inspection recommendations and requirements

As part of the prefill procedure, a check shall be made on the condition of the RPV based on the valve
manufacturer’s recommendations. This check may be performed in a number of different ways
depending upon the type of the RPV.

6.1.1 Visual inspection

The valve shall be visually inspected to ensure that the RPV mechanism does not appear damaged or
compromised. The visual inspection shall check that the RPV does not appear to have been removed
or damaged by an end user or contaminated with dirt, debris, oils, or other contaminants. A cylinder
with a compromised valve shall be removed from service.

6.1.2 Functional test

The functionality of the RPV of every valve shall be checked prior to each filling:

• Open the cylinder valve or bundle of cylinders main valve to check for residual pressure;

• If gas is emitted, the cylinder or bundle of cylinders may be filled;

• If no gas is emitted, the functioning of the residual pressure device shall be checked;

• If the check shows that the residual pressure device has retained pressure, the cylinder or bundle
of cylinders may be filled;

• If the check shows that the residual pressure device has not retained pressure, the internal
condition of the cylinder or bundle of cylinders shall be checked for contamination;
1
References are shown by bracketed numbers and are listed in order of appearance in the reference section.

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EIGA DOC 64/16

• If no contamination is detected, the cylinder or bundle of cylinders may be filled following repair or
replacement of the residual pressure device; and

• If contamination is detected, a corrective action shall be carried out, for example set aside for
further examination.

The functional test does not apply to new cylinders or cylinders that are returning to service from
maintenance, where the valve was removed from the cylinder so there is no pressure in the cylinder.

NOTE For VIPRs, this check of condition may involve establishing that residual pressure has been retained
before the start of filling and that the pressure regulator is functional at the end of filling.

6.2 Fill connectors

The design dimensions of RPVs and fill connectors vary between manufacturers. Even minor
dimensional differences of fill connectors or RPVs can result in the incompatibility of a connection.

Fill connectors used to fill cylinders equipped with RPVs shall be mechanically compatible with the
RPV (for example, pin condition including length) and chemically compatible with the gas in
accordance with ISO 15996, Gas cylinders—Residual pressure valves—General requirements and
type testing, ] ISO 11114-1, Gas cylinders—Compatibility of cylinder and valve materials with gas
contents—Part 1: Metallic materials and ISO 11114-2, Gas cylinders—Compatibility of cylinder and
valve materials with gas contents—Part 2: Non-metallic materials [3, 4, 5].

The fill connector supplied or recommended by the valve manufacturer should be used unless the
RPV and fill connector have been manufactured to standardized dimensions in accordance with
national or international standards (for example, CGA V-1, Standard for Compressed Gas Cylinder
Valve Outlet and Inlet Connections [6]).

Standardized RPV fill connectors and valves should be marked after the connection number, for
example: 540R and 320R. In these examples, the “R” indicates the valve meets the standardized
connection in CGA V-1 [6] and any fill connector marked similarly (for example: 540R, 320R) can be
used with the valve.

WARNING: Use of an improper RPV fill connector could damage the RPV and/or fill connector or fail
to fully actuate the residual pressure device within the RPV. An improper fill connector in oxygen (or
other oxidizer) service can lead to ignition that can result in property damage, personal injury, or
death.

6.2.1 Types of fill connectors

There are two basic types of RPV fill connectors: fixed pin and retractable pin. The fixed pin fill
connector has a fixed actuation pin attached to the end of the filling nipple. The retractable pin design
has a spring-loaded actuation pin incorporated in the filling nipple and for some designs the pin can
be completely retracted for filling standard valves (see Figures 1 and 2). When using retractable pin
type fill connectors, care shall be taken in selection and use to prevent inadvertent disengaging of the
retracted pin.

Figure 1—Example of a fixed pin adapter

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EIGA DOC 64/16

Figure 2—Example of a retractable pin design

6.2.2 Materials of construction for pins

As the pin of the RPV fill connector is in the flow path of the gas, material selection and cleanliness is
very important because mechanical loading and flow velocities around the pin are higher than through
standard fill connectors. Therefore, materials compatible with oxygen and other oxidizing gas services
shall be selected for these conditions.

6.2.3 Precautions to be taken when handling fill connectors

When connecting the fill connector to the cylinder valve outlet, ensure the fill connector pin is not
damaged during insertion and that the pin does not score the outlet thread and/or sealing surface.

When fill connectors are not in use, ensure there is protection from impact damage to prevent
bending of the pin. In addition, ensure the fill connector is protected from contamination such as dirt,
debris, and oils.

6.2.4 Condition, maintenance, and inspection of fill connectors

Prior to using a RPV fill connector, it should be inspected for significant wear of all components
especially for the condition of the actuation pin. Any fill connectors with a bent or broken actuation pin
shall be repaired or replaced before next use.

If polymeric or elastomeric seals are used on the fill connector, these seals shall be inspected before
each use and replaced when visibly worn, frayed, cracked, or otherwise damaged.

6.2.5 Filling mixed loads

Care shall be taken when mixed populations of cylinders with both RPV and conventional valves have
to be filled together on the same manifold. This can result in the transfer of potentially impure gas
from those cylinders fitted with conventional valves to those that are protected in use by a RPV. One
measure that can be taken to avoid such cross contamination is to vent cylinders without RPVs before
connecting to the manifold.

6.3 Installing residual pressure valves into cylinders

RPVs shall be installed in accordance with established operating procedures (for example, ISO
13341, Gas cylinders—Fitting of valves to gas cylinders [7]). In order not to compromise the
functionality and to obtain the benefits of a RPV, an internal visual inspection of the cylinder shall be
performed to ensure that the cylinder is in good condition and free of all contaminants such as debris
and visible moisture.

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EIGA DOC 64/16

6.4 Devalving cylinders equipped with residual pressure valves

For all devalving operations, care needs to be taken to ensure that the cylinder contains no pressure.
The devalving guidelines in CGA P-38, Guidelines for Devalving Cylinders; EIGA Safety Information
18, Devalving Gas Cylinders; or ISO 25760, Gas cylinders—Operational procedures for the safe
removal of valves from gas cylinders shall be followed [8, 9, 10].

A particular concern when removing valves with RPVs from cylinders is that the operator believes that
the cylinder is empty after venting because no gas is being emitted from the open valve. After venting,
it is necessary to attach a fill connector to allow the residual pressure to be released from the cylinder.

Before devalving, the operator shall confirm that the cylinder is empty of all pressure. A small amount
of inert gas or air shall be introduced into the cylinder through the valve outlet and fill connector to
verify whether or not the gas flows unhindered into the cylinder.

7 References

Unless otherwise specified, the latest edition shall apply.

[1] International Carriage of Dangerous Goods by Road (ADR), United Nations Economic Commission
for Europe www.unece.org

[2] EIGA Doc 95, Avoidance of Failure of Carbon Monoxide and of Carbon Monoxide/Carbon Dioxide
Mixtures Cylinders, www.eiga.eu

NOTE This publication is part of an international harmonization program for industry standards. The technical
content of each regional document is identical, except for regional regulatory requirements. See the referenced
document preface for a list of harmonized regional references.

[3] ISO 15996, Gas cylinders—Residual pressure valves—General requirements and type testing,
www.iso.org

[4] ISO 11114-1, Gas cylinders—Compatibility of cylinder and valve materials with gas contents—Part
1: Metallic materials, www.iso.org

[5] ISO 11114-2, Gas cylinders—Compatibility of cylinder and valve materials with gas contents—Part
2: Non-metallic materials, www.iso.org

[6] CGA V-1, Standard for Compressed Gas Cylinder Valve Outlet and Inlet Connections
www.cganet.com

[7] ISO 13341, Gas cylinders—Fitting of valves to gas cylinders, www.iso.org

[8] CGA P-38, Guidelines for Devalving Cylinders, Compressed Gas Association, Inc., 14501 George
Carter Way, Suite 103, Chantilly, VA 20151. www.cganet.com

[9] EIGA Safety Information 18, Devalving Gas Cylinders, www.eiga.eu

[10] ISO 25760, Gas cylinders—Operational procedures for the safe removal of valves from gas
cylinders, www.eiga.eu