A Mini Project Report

On

STUDY OF MANUFACTURING PROCESS OF LPG

CYLINDERS
Submitted to
J.N.T.U. Hyd in partial fulfillment of the
Requirement for the award of Degree in

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

Submitted by
P .ANIL
Under the Guidance of

ASST PROF. D.VINAY KUMAR

DEPARTMENT OF MECHANICAL ENGINEERING
PRRM ENGINEERING COLLEGE
(Approved by AICTE , Affiliated to J.N.T.University,HYD)

SHABAD-509217.

1
 PATNAM RAJENDAR REDDY MEMORIAL
ENGINEERING COLLEGE
(Approved by AICTE , Affiliated to J.N.T.University,HYD)

SHABAD-509217.

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE
This is to certify that the dissertation entitled

STUDY OF MANUFACTURING PROCESS OF LPG

CYLINDERS
Was successfully carrier out by
Name: P.ANIL (HT NO) : 11611A0373
At
PATNAM RAJENDAR REDDY MEMORIAL
ENGINEERING COLLEGE
SHABAD

In partial fulfillment for the award of the degree of Bachelor of technology in

Mechanical engineering for the academic year of 2014-2015
Signature of Project Guide Signature of Head of the Department
Assoc prof. D. VINAY KUMAR Prof. S.NARASHIMHA
Signature of the External examiner Signature of the Principal
Prof. M.SITHA RAMA RAO

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 ACKNOWLEDGMENT
I thank the almighty for giving me the courage and perseverance in
completing the project.Though the following dissertation is an individual work,
I could never reach the heights or explored the depths without the help
support, guidance and efforts of a lot of people. So, with great pleasure I utilize
this opportunity to express my deep sense of gratitude.

It is with fathomless gratitude that I express my benevolent thanks to

Prof. M. SITA RAMA RAO, Principal of PRRM Engineering College, Shabad for
permitting me to pursue this project in R.M. Cylinders Private Limited.

I profusely thank my project guide Mr. S. NARSIMHA, Head Of the

Department (H.O.D) of Mechanical Engineering, PRRM Engineering College
for the infrastructure and all other essential facilities and encouragement
given to me during the project work.

I express my deepest gratitude towards Mr. SATYANAND and Mr. D. VINAY

KUMAR , Department of Mechanical Engineering, for their scholastic guidance,
undeterred support and valuable suggestions in my graduation.

I am beholden to Mr. C. ANIL REDDY, Asst. Professor, Department of

Mechanical Engineering, for his excellent support, patience and ideas made to
start this project possible and he has been painstakingly congruous with his
guidance.

I should be failing in my duties if I don’t mention the help of authors of

journals and books, the pillars of my project work.

Project Associates
P.ANIL (HT NO):11611A0373

PRAVEEN KUMAR DAS (HT NO):11611A0372

M.KARTHIK (HT NO):11611A0355

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 ABSTRACT

 Liquefied Petroleum Gas (LPG) cylinders plays critical role to

contain and transport hazardous LPG in its lifecycle. LPG cylinders in
India are designed, manufactured and tested as per Indian standard
IS 3196 to ensure that they are safe and are compiled to minimum
required specifications.

 To manufacture LPG cylinders first sheet is cut to size on cutting

machine to make blanks. These blanks are now deep drawn on deep
drawing power press to two halves of the cylinder. Other parts such
as foot ring, backing strip, top ring and turned components are
manufactured separately. Now both the halves are joined with a
backing strip prior to their welding. After welding complete cylinder
undergo stress relieving normalizing process in suitable heat
treatment furnaces.

 So we have decided to study the manufacturing process of the

cylinder in large scale in a industry. We will consider all the
manufacturing details to setup a industry to manufacture in different
sizes and to the market.

INDEX
4
CONTENTS Page. No.

1. Introduction

2. Objectives

3. Parts to be required

3.1. Valve protecting ring

3.2. Vertical stays

3.3. Bung

3.4. Upper and lower halves

3.5. Foot rings

4. Manufacturing process

4.1. Raw material

4.2. De-coiling
4.3. Deep Drawing
4.4. Trimming
4.5. Bung hole piercing
4.6. Degreasing
4.7. Bung inspection
4.8. Bung welding
4.9. Footring welding
4.10. Joggling
4.11. C-Welding
4.12. Stay plate
4.13. V.P Ring

5
 4.14. V.P.Ring to Stay plate welding
4.15. V.P Shroud on body (Body welding)

4.16. Heat Treatment

4.17. Hydrostatic Testing
4.18. Grit Blasting
4.19. Metalizing
4.20. Painting
4.21. Internal Cleaning
4.22. Valve Fixing
4.23. Tare Weight And Punching
4.24. Screen Printing And stenciling
4.25. Pneumatic Testing

5.Inspection and quality control

6. Conclusion.

1.INTRODUCTION
6
 LPG Cylinder is an essential item for filling liquefied petroleum
gas used for various purposes.To ascertain the quality, safety
and performance certain regulations are applicable such as BIS
standardization and Explosive License etc.

Fig 1

LPG (Liquified Petroleum Gas = propane & butane) has the advantage of
clean burning, high heati ng value and the fact that it can be kept liquid (i.e. at a
very low volume when compared to the volume of the gas) by holding it slightly
pressurerized. There are many designs and sizes of such pressure tanks from the
one way lighter to LPG tankers.LPG cylinder is sandblasted and finished with
electrostatic painting. LPG Cylinder is an essential item for filling liquefied
petroleum gas used for various purposes. To ascertain the quality, safety and
performance certain regulations are applicable such as BIS standardization and
Explosive License etc.

The L.P.G. Cylinder consists of the following parts:

7
 Valve protecting ring
 Vertical stays
 Bung
 Valve
 Cylinder upper half
 Cylinder lower half
 Foot ring

2. OBJECTIVE

8
1. Collect the press work processes and study each of the process.

2. Collect the welding processs and study each of the process.

3. Study the Heat treatment process.

4. Study the each step of assembling and decide the number of

assembling fixtures.

5. Study the inspection procedure of cylinder

6. Study the painting process as per BIS code.

7. Study the steps and process of storing and dispatching the

cylinders to various places.

8. Study the process cost and profit.

3. PARTS TO BE REQUIRED

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The following are the major parts to be required for the
manufacturing of L.P.G. cylinder :

3.1. VALVE PROTECTING RING:

 The pipe/tube used for making of V.P (Valve protecting).

 Ring shall be Medium carbon steel, shall confirm to IS

1239:2004.

 Dimensions:

 VP Ring dia : 220 ± 3 mm

 Pipe/tube dia : 21 mm

 Weep hole dia : 2 mm

Fig 3.1.

MAKING PROCEDURE:

1) Take the 6 m long tube of 21mm outer diameter.

2) Set the hallow tube in position on the rolling tool. The cylindrical portion
of the rolling tool must have diameter equal to inner diameter of valve
protection ring i.e.220 mm.
3) Complete the spring type shape of the job.
4) Clamp the spring shaped tube by using fixture.

10
 5) Cut the spring shaped tube at one side which is formed the rolling tool
with the help of vertical band saw.
6) Press the two ends of two circular shaped tube. Then hold it in a fixture
and weld it.
7) Flattering is done with a flattering press.

3.2. VERTICAL STAYS:

The sequence of stay plate up to marking and forming is:

 The raw material Low carbon steel is used, shall confirm to IS

6240:2008.

 The marking on the stay plate is done as per approved drawing using
mechanical stay stamping machine with proper fixture to ensure equi-
spaced marking in a straight line.

 Emboss serial number, Tare weight, Maximum gross weight, Indian

standard number, Maximum working pressure, Tearing pressure and
Tested date on the vertical stays with help of stamping tool.

 Stay plate dimensions :

 52*120 mm – 2 No's

 91*120 mm – 1 No's

Fig 3.2.

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3.3. BUNG:
 Ram material used for bungs is “ Mild steel”, shall confirm to IS
9121:2005.

Fig 3.3.

MAKING PROCEDURE:

1) Hold the M.S. round bar in the collet chuck.

2) Face the bar.
3) Turn to 60mm diameter for 23mm length.
4) Step turn to 52mm diameter for 13mm length from faced end.
5) Mark the center of the hold to be drilled with the help of center drill.
6) Drill 15mm diameter hole,
7) Taper boring is done with the help of taper bore.
8) Cut internal threads using tap.
9) Parting is done using parting tool.

3.4. UPPER AND LOWER HALVES:

 Cylinder Halves for cylinder shall be made from Circles by deep drawing
using suitable size Press, Die & Punch.The Agreed minimum finished
thickness of 2.53 mm for halves after deep drawing should be
checked.

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 UPPER HALVE LOWER HALVE

Fig 3.4.1. Fig 3.4.2.

MAKING PROCEDURE:

1) Take the M.S. Sheet of 610 ± 1 mm diameter circle.

2) Perform drawing operation on the blank with the help of draw tool.
3) After completion of the draw, side circular cutting is done with the help
of circular cutting machine.
4) Bung hole of 52 ± 0.3 mm diameter is made on the upper half with the
help of piercing tool.

3.5. FOOT RINGS :

 Material required for the footring is M.S. Sheet of 840mm * 60mm.

Footring dimensions:
Outer Diameter : 265 ± 3mm
Height : 44 ± 2mm
Thickness : 2.9 ± 0.1mm
‘ O’ Form radius : 8mm
Vent hole size : 12 * 25 mm – 6 No’s
Drain hole size : Ø5mm – 8 No’s

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 4.MANUFACTURING PROCEDURE

4.1. RAW MATERIAL

 Raw material used for manufacturing cylinder is “Low carbon steel”, shall
confirm to IS 6240:2008.

 Coil size : 2.9 * 1680 mm

2.9 * 1150 mm

 Thickness : 2.90 ± 0.1 mm

14
 Fig 4.1.

 Cylinder body steel should conform to IS6240. Presently HPC approved steel
suppliers are M/s SAIL, TISCO, ESSAR, SSP, ISPAT, LLOYDS and JINDAL.
Manufacturers are authorized to use steel only from these suppliers or from
any other supplier / import source after taking HPC approval. The
minimum thickness of steel sheet / coil for manufacture of body shall be
2.9 ± 0.1 mm. Steel Coil may be used by manufacturer having de-coiling
facilities approved by BIS. However, manufacturer must obtain approval
from CCOE Nagpur, for the calculations for the thickness of steel plates for
steel plates supplied by various manufacturers, various types of steel i.e. IS
6240 latest edition.

4.2. DE-COILING:

* The hot rolled steel coils are cut into circles using rotary cutters of de –
coiling machine.

 Parameters:-
1. Circle Dia : 610 ± 1 mm

2. Thickness : 2.9 ± 1 mm

15
 3. Surface defects : No surface defects like

cut marks, pit, corrosion, slivers, lamination etc.

Fig 4.2

 Sheet shall be decoiled on decoiler & circles of required size shall be cut.
During cutting of the circles care shall be taken to have proper circle
with uniform edge.

4.3. DEEP DRAWING:

 The circles are taken to deep drawing operation and converted to halves
on a deep draw press.

16
 Fig 4.3

 Cylinder Halves for cylinder shall be made from Circles by deep

drawing using suitable size Press, Die & Punch.The Agreed minimum
finished thickness of 2.53 mm for halves after deep drawing should be
checked.

4.4. Trimming:
 Trimming shell be done with the help of a fixture so as to correct height
of halves is maintained across the circumference.

 Parameters:
 Internal diameter : 314.1 + 1%

 Halve height : 250 ± 1 mm

17
  Minimum thickness : 2.43 mm

 Profile regularity : Semi-ellipsoidal design.

Fig 4.4.

4.5. BUNG HOLE PIERCING:

 Bung hole piercing is done with the help of a fixture that locates halve
and ensure non-eccentric piercing of bung hole so that rejection due to
eccentricity is eliminated at that process.

 Parameter:
 Bung hole dia : 52 + 0.3 mm

 Bung hole eccentricity : 2 mm max.

18
 Fig 4.5

4.6. DEGREASING:
 Degreasing is done with caustic soda solution at minimum temperature
of 80 c so as to make the surface of halves free from oil, grease, dirt or
any other deposits.

 sequence of degreasing operation:

Clean with hot caustic soda solution (80⁰ c)

Wipe and clean with cotton Rinse with plain water

Inspection.

19
 Fig 4.6

4.7. BUNG INSPECTION:

 Ram material used for bungs is “ Mild steel”, shall confirm to IS
9121:2005.

 Bungs are checked for its thread as per the requirement, for which dial
gauge setup shall be adapted for checking bung internal threads.

 Angle gauge is used to check the collar angle of 15º

Fig 4.7

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4.8. BUNG WELDING:
 Bung welding is carried out With the help of automatic MIG welding
process.

 The complete fusion and penetration of weld joint is ensured by strictly

maintaining the parameters

Fig 4.8

 Parameters:
 Current : 200-260 A

 Voltage : 28-32 V

 Speed : 13-15 sec/rev

 No of round : Two

 Wire size : Ø1.2 mm

 Gas flow rat : 15-20 ltrs/min

 Gas composition : 92% Argon and 8% CO2.

21
  Acceptance criteria : No weld defects like blow
hole, porosity, under cut, crater, lack of fusion and
burn-out.

4.9. FOOTRING WELDING:

 The foot ring welding operation is carried out with the help of rotation
based automatic fixture to ensure non eccentric foot ring with respect to
body which ensuring equi spaced and equi length welds.

 Foot ring joint shall be positioned at the center of any one of the foot ring
weld to body.

 Parameters:
 Weld length : 45 mm

 Ground clearance : 10 mm

Fig 4.9.

 Foot Ring sheet Forming, Punching, Stamping facility should be available

in-house. Welding of Foot Ring pipe & sheet shall be continuous along
the full circumference of pipe. Foot Ring joint should be properly grinded.

 Punching of 6 nos. vertical slots should be done on a punching

machine/press (manual not allowed) with proper fixtures to ensure equi-
spaced positioning of slots.

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4.10. JOGGLING:
 Joggling shall be used as a method of fitment of halves for

C-welding operation.

 Only upper halve shall be joggled.

 Joggling joint shall halve an overlap of minimum “3 times of agreed

finished thickness”.

 Parameters:

 Jogging height : 9 ± 1 mm

Fig 4.10.

 Proper buffing must be done before welding to ensure proper fitment /

welding and a dust free surface. Backing strip method will not be
acceptable.

 Examination for Circularity, Surface Defects, and Profile Regularity,

Straightness and Verticality & internal cleaning shall be carried out before
closing-in Operation.

23
4.11. C - WELDING:

C-welding is carried out with the help of automatic MIG welding

process.

 The ratio of width of weld to the height of weld shell is ¼.

 Weld surface shall have smooth contour and shall be free from under
cuts.

 The complete fusion and penetration of weld joint is ensured by strictly

maintaining the parameters.

 Parameters:
 Current : 350-450 A

 Volts : 32-38 V

 Speed : 80-85 sec/rev

 No of rounds : One

 Wire size : Ø 1.2 mm

 Gas flow rate : 15-20 ltrs/min

 Gas composition : 92% Argon and 8%

 Acceptance criteria : No weld defects like blow

hole, porosity, under cut,
lack of fusion.

 Qualified welders are employed for C-welding operation.

24
 Fig 4.11.1.

Fig 4.11.2.

 Welding consumables used shall be such that the desired properties of

the weld are obtained and the physical values of the welded metal are not
lower that the specified values of the parent metal. The chemical
composition of the weld metal shall be compatible with that of the parent
metal.
 Welding procedure and Welder’s Performance Qualifications should be
as per the requirements of IS 3196(part1):2006 & welding shall be
carried out by such approved welders only.
 Before welding, the surface shall be free from scale, grease, oil and dirt.

25
  All welding activity should be completed before heat treatment.
 Manual welding shall not be permitted for Circumferential welding.
 Welding parameters for Circumferential shall be specified on the drawing
approved by CCOE/BIS.
 Traceability of the welding machine deployed for the circumferential weld
joint shall be maintained by way of punching the welding machine no. at
the footring OR 91mm Stay plate of the cylinder.
 Radiography of the weld samples for each welding machine deployed for
Circumferential welding shall be carried out on half yearly basis to
ensure proper functioning of the machine.

4.12. STAY PLATE:

 The sequence of stay plate up to marking and forming is:

 The raw material Low carbon steel is used, shall confirm to IS

6240:2008.

 The stay plates are blanked from circle cutting corners .

 After blanking, the stay plates are ensured for no sharp edges and
uniformity in the size.

 The marking on the stay plate is done as per approved drawing using
mechanical stay stamping machine with proper fixture to ensure equi-
spaced marking in a straight line.

 Stay plate forming with respect to V.P. Ring diameter is done using
mechanical press with proper fixture.

 Stay plate dimensions:

 52 * 120 mm – 2 No's

 91 * 120 mm – 1 No's

26
 Fig 4.12.

4.13. V.P RING:

 The pipe/tube used for making of V.P (Valve protecting).Ring shall be

Medium carbon steel, shall confirm to IS 1239:2004.
 The pipes/tubes are procured from reputed supplier and getting it
converted to ring by won source.

 Dimensions:

 VP Ring dia : 220 ± 3 mm

 Pipe/tube dia : 21 mm

 Weep hole dia : 2 mm

27
 Fig 4.13.

4.14. V.P.RING TO STAY PLATE WELDING:

 This is done with the help of a fixture that ensures non-eccentric, equi-
spaced and vertical stay plates on V.P.Ring.

 V.P.Ring joint is positioned approximately at the centre of one of the stay

plate and welding is done manually on both sides of the stay plate to ring
joint

Fig 4.14.

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  Welding of Stay Plates to VP Ring should be done in-house with the help
of a fixture to ensure non-eccentric, equi-spaced and vertical assembly.
The stay plates shall be of uniform thickness & size with no sharp edges.

 The weep-hole shall be positioned between two stay plates. VP Ring joint
should be properly grinded and centrally positioned in one of the stay
plate welding. Welding of the VP ring to the stay plate shall be done from
both the sides.

4.15. V.P SHROUD ON BODY (BODY WELDING):

 Fixture is used so that V.P. Shroud is properly located with respect to
bung hole to ensure non-eccentric welding.

 MIG welding is used for the operation and welding is performed on both
sides of V.P.Shrouds to body joint.

 Parameters:

 Overall height : 625 ± 5 mm

 V.P.Ring eccentricity : 3 mm, max.

 Verticality of cylinder : 10 mm/1000 mm max.

Fig 4.15

29
  The assembly should be welded to the cylinder body using suitable fixture so as to
ensure non-eccentric welding with respect to the bung hole. Welding of the VP ring stay
plate to be done on both the sides of stay plates.

4.16. HEAT TREATMENT:

Fig 4.16

 After completion of all welding operations, cylinders are subjected to heat

treatment that to relive the residual stresses without altering the
metallurgical structure of steel.

 Continuous furnace is used for heat treatment process.

 Parameters:

 Temperature : 650 – 670 ºc

 Soaking time : 12 minutes

 Cycle time : 25 minutes

 No of burners : 4 no’s

 No of thermocouples : 2 no’s

 Door opening duration : 60 sec.

30
  No of rows : 2

 Capacity/hour : 60cyl * 2 rows =120 cylinders.

4.17. HYDROSTATIC TESTING:

 After heat treatment of cylinders, the cylinders shall be subjected to
hydrostatic testing as per IS 3196:2012.

Fig 4.17

 Number of pressure gauge should be equal to the number of testing

points with positive segregation.
 Cylinders should be dried totally and only after ensuring the same the
cylinder should be tested at pressure as specified by the statutory
agency/BIS, which should be retained for minimum 30 secs. {Current
specs is 2.45 MPa (25.00 kg/cm 2), however, in case of any change
notified by BIS, test has to be carried out accordingly}.
 The HST fixture should be roller based rotating type.

31
  Arrangement to be made for inspection of cylinder from all the sides and
bottom portion during the test the water filling equipment preferably
should be pneumatically operated and should have auto fixing, auto
filling and auto evacuation to avoid spillage of water on the outer surface
of cylinder under test.
 A wooden / Teflon mallet shall be used to tap the cylinder specially at the
C-weld during HST to detect pin hole, porosity and other weld defects if
any.
 Release test pressures applied and evacuate water inside cylinder.
 Clean and dry the cylinder internally.

4.18. GRIT BLASTING:

 The external surface of cylinder including V.P.Ring assembly and inside
bottom of foot ring shall be grit blasted after heat treatment and HST by
using airless grit blasting machine.

 The quality of grit blasting in shadow zone of foot ring and V.P.Ring to
stay plate assembly shall be checked for complete satisfaction.

Fig 4.18

32
  Each cylinder should be grit blasted after heat treatment & HST test as
per IS 3196 (Part-I):2006.
 The surface finish of cylinder after grit blasting shall be as per grade
SA2.5.

4.19. METALIZING:
 The entire surface of cylinder including V.P.Ring assembly and inside
bottom of foot ring shall be metalized immediately after grit blasting.

 Uniform coating of minimum 40 micron shall be applied on cylinder.

Fig 4.19

 Surface preparation is required to be done to remove any deposition in

the cylinder surface before metalizing & to provide surface finish of SA
2.5.
 Surface preparation must be done as per IS 3196 (Part 1): 2006. A
pictorial representation as per IS: 9954 shall be used for confirming
the finish of the surface preparation of SA 2.5.Cylinder shall not be
kept waiting after grit blasting and shall be metalized immediately to
prevent rusting.

33
  Uniform zinc metallising coating of minimum 40 micron should be
applied on each cylinder.
 The Zinc wire used for metal spraying (metallising) should conform to
IS: 12447 (latest).
 Adhesiveness of Zinc coating on the cylinder surface shall be checked
as per test method given in IS 5906:1989 (Standard for sprayed
aluminium and Zinc coating on iron & steel- Specifications).

4.20. PAINTING:
 After metalizing, the cylinders are applied for one coat of zinc chromate
red oxide primer and one coat of signal red of synthetic enamel each of
minimum 15 micron thickness uniformly all over the body and bottom of
foot ring and inside portion of V.P.Shround assembly.

Fig 4.20

 Zinc chromate primer as per the specifications of IS: 2074 (latest) and
procured from Asian paints / Goodlass Nerolac / ICI Limited / Berger
paints / Shalimar paints to be used.
 The primer has to be applied immediately after Zinc metallising. The
primered cylinder surfaces shall have to be force dried at approximately
80 degree Celsius.

34
  Movement of cylinders in/out of oven/blower shall be through a conveyor
to prevent any manual handling of cylinders till it completely dries.
 The length of the conveyor system should be such that after the cylinder
comes out of drier, it moves on the conveyor for at least 3 hrs before it is
taken for next application of paint / next activity & shall be in no case
less than 60 mete r.
 Provision of facility for drying of paint using Oven/ Hot air & conveyor for
movement of cylinder is essential.
 The air used for both the paint application shall be completely dried
using refrigeration based air drier.
 Top top surface of bung shall be applied for zinc chromate primer
only. Signal red paint not to be applied on bung.

4.21. INTERNAL CLEANING:

 Cylinder internal are to be cleaned thoroughly by using air, magnet,
cotton cloth and light etc. so as to clean the internal surface of the
cylinder and remove all the foreign material, rust and water traces.

 The air used for internal cleaning shall be completely dried enough using
refrigeration based air drier.

 Bung thread shall be cleaned using ¾” 14 NGT tap & with soft wire
bursh before fixing the valve on the cylinder.

4.22. VALVE FIXING:

 1. The LPG valve is made of brass metal, shall confirm to IS 8737:1995.
 2. Apply minimum two rounds of Teflon tape on the valves before
fitment.

 3. Valves are then fitted on the cylinder bung thread. Valve torque shall
be 145 ± 15 lbft.

35
 Fig 4.22

 Valve tightening is to be carried out on Valve on-off Tightening

Machine with provision to set & check the tightening torque. Provision
of Valve on-ff Tightening Machine with provision to set & check the
tightening torque is essential.

 Finished cylinder should be stacked vertically with safety cap fitted on

valve.

 Valve fitment area flooring should be free from dust, laid with
concrete and rubber mats should be laid on concrete area.

4.23. TARE WEIGHT AND PUNCHING:

 The tare weight of cylinder includes weight of valve and safety cap.

36
  The weighing scale shall be of 50/60 kg capacity electronic type with
least count not more than 10 grams.

 The weighing scale shall be calibrated using standard weights at least

once in a shift.

 Tare weight shall be punched on bung as well as stay plate.

 Gross weight of cylinder (14.2 + actual weight of cylinder) also to be

punched on stay plate.

 Minimum tare weight of the cylinder shall be 15 kg. Cylinders with more
than +/- 50 grams variation between the actual and stencilled tare
weight, subsequent to rounding off as per Indian standard code IS : 2,
shall not be accepted.

4.24. SCREEN PRINTING AND STENCILING:

Screen printing shall be done for tare weight, slogans and logo as per the
requirement of the customer and as per approved drawing.

 The letters with shabby/blurred edges shall be avoided during screen

printing.

Fig 4.24

37
  Proper fixture / locators for ensuring positioning and alignment of
Logos / Slogans / Tare Weight / Test dates with respect to the locators
on the body as per drawing should be used.

 Slogans to be screen printed :

A) Switch off regulator when not in use
b) Check seal on delivery &
C) For Domestic use only is to be screen printed both in
Hindi & English

4.25. PNEUMATIC TESTING:

 The cylinder filled with air to 1.18Mpa pressure and immersed in the
tank for testing. The duration of testing is 60 sec.

 Proper provision to be made for rotating the cylinder during the test to
detect leakage. Testing shall be carried out after fixing the safety cap on
the valve.

 Air filling/remove adapter shall be of the design approved by the

customer and should not damage the valve pin.

Fig 4.25.1

38
 Fig 4.25.2

 The inside of the tank for pneumatic test should be clean and painted
with white paint.

 After air evacuation, presence and correct position of joint packing (O-
Ring) in the Valves to be checked .Air supplied to the Pneumatic test
shall be completely dried by using referigeration based Air Drier.
Provision of Referigeration type air drier is essential.

 Optimum illumination to be ensured at HST and pneumatic test stages

 In case there is any change in Test specifications by BIS, testing has to
be carried out accordingly.

 All other tests like Hydrostatic stretch test, burst test, volumetric
expansion test etc. as specified in IS: 3196 Part III latest shall be carried
out by manufacturer.

 Each cylinder should meet requirement of WATER CAPACITY, as

specified in IS3196 (Part1):2006.

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 5. INSPECTION AND QUALITY CONTROL

An item or component of product which is manufactured is required to perform

certain functions. The science of checking whether a component actually doe
so are not is called INSPECTION.

In another words, INSPECTION means checking the acceptability of the

manufactured product.

A QUQLITY CONTROL SYSYTEM performs inspection, testing and

analysis to conclude whether the quality of each product is as per laid quality
standards or not. It is called STATISTICAL QUALITY CONTROL ( S.Q.C ) when
statistical techniques are employed to control quality or to solve quality control
problems.

CONTROL is a system for measuring and checking a phenomenon. It

suggests when to inspect, how often to inspect and how much to inspect. In
addition, it incorporated a feedback mechanism which explores the causes of
poor quality and takes corrective action.

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 6. CONCLUSION.

 By this project we have known the entire manufacturing

process of the cylinder from the raw material to quality
cylinder product output.

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