and missed this post...
Darlene,
I completely agree that the cylinder should have been hydrostatically retested. But...remember that an aluminum cylinder can have a hole in the crown or sidewall and still pass the hydro retest.
As a PSI inspector, I would have had the cylinder hydro retested and then visually inspected based upon the known history. For good measure, I would have then used Eddy Current technology (note: one should be properly trained and have sufficient experience with EC use with alloys other than 6351) to ensure the integrity of the cylinder.
Aluminum cylinder manufacturers indicate that cylinders have an expected life of over 100,000 fills to working pressure or 10,000 fills to hydro retest pressure.
While the practice of filling an AL 80 to 4000 psig is not the smartest thing in the world, it will not in itself render the cylinder as unusable.
ALL of my cylinders have the fill pressure and my name written across the crown of the cylinders in indelible black marker. This is a reminder for all of the Fill Station Operators.
When asked how much I want in the cylinders, I point to the crown and state the working pressure.
If filling to working pressure using manufacturer guidelines (300-600 psig/min), I can fill an AL80 to 3000 in a little over 10 minutes and have no appreciable loss of pressure later. The cylinder is not hot to the touch.
So...my recommendation is "When in doubt...check it out!"
Chris
COVCI