MANUFACTURING AND TESTING OF LIQUIFIED PETROLEUM GAS CYLINDERS

PREPARED BY:- UTKAL KUMAR SWAIN 1011018261 MECHANICAL ENGG.

CONTENTS INTRODUCTION INDIAN STANDARD

RULES TYPES OF CYLINDER

MANUFACTURING TWO PIECE CYLINDER

MANUFACTURING TESTING OF

CYLINDERSI. WATER CAPACITY TESTII. HYDROSTATIC TEST BURST AND NOMINAL HOOP

STRESS CONCLUSION

INTRODUCTION India is the third largest LPG consumer of in domestic sector

in the world. Liquefied Petroleum Gas (also known as LPG or LP Gas)

Cylinders in India are produced as per Indian standard, Welded low carbon steel cylinders exceeding 5 liter water capacity for low pressure liquefiable gases, IS 3196 (part 1):2006.

The testing of these cylinders are done according to the Indian Standard, IS 3196 part 3.

These tests are important to ensure that the design and construction of cylinders are safe and compiled to standards.

Approximately 3 million LP Gas cylinders are delivered to Indian homes every day and all these cylinders are manufactured and tested according to the Bureau of Indian Standards before they are released into the market.

BUREAU OF INDIAN STANDARDA. IS3196 PART 1: Welded low carbon

steel cylinders exceeding 5 liter water capacity for low pressure liquefiable gases.

B. IS3196 PART 3: LP Gas cylinders are produced in batches and one random cylinder out 202 cylinder batch undergoes a acceptance test for material quality verification.

C. IS6240: Hot Rolled Steel Plate (up to 6 mm) Sheet and Strip for the Manufacture of Low Pressure Liquefiable Gas Cylinders.

D. IS 2074 and IS 2932 : for painting zinc chromate redoxide and synthetic enamels are used at 15 microns minimum.

TYPES OF CYLINDER MANUFACTURING

Two piece cylinder manufacturing: In two piece construction, cylinders are fabricated by welding two domed ends directly together.

Three piece cylinder manufacturing: A three piece cylinder is fabricated by joining two domed ends to a cylindrical body.

In case of two piece cylinder manufacturing there is only one circumferential weld where as in three piece cylinder construction there two circumferential welds.

In three piece cylinder construction there is a longitudinal weld.

Two piece cylinders are used for domestic purposes while three piece cylinders are used for automobile or commercial purposes.

TYPES OF CYLINDER MANUFACTURING

TWO PIECE CYLINDER THREE PIECE CYLINDER

TWO PIECE CYLINDER MANUFACTURING

RAW MATERIAL: Low carbon mild steel with 25% elongation, yield strength of 240 N/m² and ultimate tensile strength between 350-450 N/m².

The design wall thickness of the cylinder should be t= 2.43 mm.

The steel is passed through a roller which makes the uniform surface.

Online shearing machine : The mild steel is cut into circles of diameter 613 mm.

Deep drawing machine: The upper and lower halves of the cylinder are made.

Punch machine: A hole is made on the upper half for fixing the BUNG or valve pad.

Bung is welded to the upper half and foot ring is welded to the lower half.

TWO PIECE CYLINDER MANUFACTURING

Two halves are assembled together by the method of juggling and MIG welding.

In MIG welding a mixture of argon(92%) and carbon dioxide(8%) is used.

Valve protection ring is welded on the top of the cylinder.

At last serial number and manufacturing identification marks are punched on the stay plate of the cylinder.

MANUFACTURING

DEEP DRAWING

TESTING OF CYLINDERS

Heat treatment For internal stress relief Temperature-= 690-710˚c Time for heating= 42 minute Hydrostatic Test Pressure = 25.35 kg f/cm² Time = 1 minute The water is filled into the cylinder at the above

mentioned pressure. To check whether there is any leakage in weld

joints.

HEAT TREATMENTFURNACE

TESTING OF CYLINDER Pneumatic Test Compressed air is filled into the cylinder. Pressure = 12 kg f/cm² The cylinder is dipped in the water. To detect thread leaks or other joint leaks. Acceptance Test To determine yield strength , ultimate strength and %

of elongation. The cylinder is cut at longitude, circumference and at

the weld section. I type sample is made from the above three pieces ,

area is calculated and then it is tested through tensile strength machine.

GRAPH

GRAPH

TESTING OF CYLINDER

Bend Test Two pieces from weld portions are taken to determine

the quality of circumference weld. Hydrostatic Stretch Test To determine volumetric expansion and permanent

expansion, Required pressure = 25 kg f/cm² C1 = Initial volume of the cylinder with water. C2 = volume of the cylinder at pressure 25 kg f/cm²

for 60 seconds. C3 = Volume of the cylinder after releasing the

pressure. Volumetric expansion = C1 – C2 Permanent expansion = C1 – C3

TESTING OF CYLINDER

HYDROSTATIC TEST PNEUMATIC TEST

Burst Test And Nominal Hoop Stress The cylinders are subjected to continuous hydrostatic

internal pressure till it bursts. s = (p * Di)/2t Where, s = nominal hoop stress at which destruction occurs p = Internal Hydrostatic Pressure at which the cylinder bursts in M pa. Di = internal diameter of the cylinder in mm t = thickness of the cylinder.

CONCLUSION

cylinder manufacturing process was described from design stage to finished cylinder. Cylinder design calculations are aimed to find thickness, which is calculated separately forcylindrical and domes portions and finalize whichever is greater. Once the design is finalized, cylinders are produced from a specified raw material through various processes. Internal stresses in cylinders are relieved in a heat treatment process. Cylinders are marked with unique serial numbers and tare weight. Various tests are conducted on cylindersto get certification from bureau of Indian standards for market circulation.

REFERNCES

Indian Standard (2012). IS 3196 (Part 3) : 2012. Welded low carbon steel cylinders exceeding 5 liter water capacity for low pressure liquefiable gases part 3 methods of test. New Delhi: Bureau of Indian Standard.

Indian Standard (1999). IS 6240 : 1999. Hot rolled steel plate(up to 6 mm) sheet for the manufacture of low pressure liquefiable gas cylinders. New Delhi: Bureau of Indian Standard.

Indian Standard (2006). IS 3196 (Part 1) : 2006. Welded low carbon steel cylinders exceeding 5 liter water capacity for low pressure liquefiable gases part 1 cylinders for liquefied petroleum gases (LPG) - specification. New Delhi: Bureau of Indian Standard.

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