EQUIPMENT FOR CNG GAS CYLINDER RE-TEST SHOP 

GENERAL REQUIREMENT FOR CNG GAS CYLINDER RETEST SHOP :

  • DEGASSING OF CNG CYLINDERS IN AN OPEN SPACE
  • REGISTRATION OF INCOMING CYLINDERS IN A SHOP
  •  BRUSHING / CLEANING OF EXTERNAL SURFACE OF CYLINDER
  • VISUAL INSPECTION OF CYLINDER FOR DENT / SCRATCH/ PITTING ETC
  • REMOVAL OF VALVE ON VALVE MOUNTING MACHINE
  •  THREAD CHECKING AND INSPECTION WITH STANDARD THREAD GAUGE
  • TARE WEIGHT CHECKING
  • INTERNALSURFACE CLEANING BY WATER JET CLEANING MACHINE
  • BOROSCOPE/ VEDIOSCOPE FOR INTERNAL SURFACE INSPECTION
  • ULTRASONIC THICKNESS MEASUREMENT- MANUAL PROBE
  • ULTRASONIC FLAW DETECTION- MANUAL PROBE
  • WATER FILLING STATION / VICE ARRANGEMENT FOR HYDRO STRETCH TEST
  • HYDRO STRETCH TEST FOR CYLINDER- JACKETED METHOD
  • LID REMOVAL VICE ARRANGEMENT
  • WATER DRAIN FROM CYLINDER AFTER STRETCH TEST
  • INTERNAL DRYER FOR CYLINDER BY HOT AIR
  • REPAINTING OF CYLINDER
  • CHECKING OF VALVE FOR LEAKAGE BY HIGH PRESSURE AIR
  • MOUNTING OF VALVE OVER CYLINDER
  • STAMPING OF ACCEPTED CYLINDER

OTHER REQUIREMENT :
• OVERHEAD CRANE / JIB CRANE FOR CYLINDER MOVEMENT
• TRANSFER CONVEYOR ARRANGEMENT

HYDRO STRETCH TEST FOR CNG GAS CYLINDERS

IS 5844    (  Water Jacket Method )

HYDRO STRETCH TEST BY WATER JACKET METHOD AS PER IS : 5844

( Hydraulic Power Pack Driven Pressure Pump System )

 

    

Machine Selection criteria :

Test Pressure Requirement :

• Normal Vehicle CNG Cylinder testing : 350 Bar capacity Machine
• CNG Cascade cylinder Testing : 600 Bar capacity Machine

Technology Used :

• Power pack driven intensifier system : High cost system
• Air driven pump system : Low Cost system

Operational Interface :

• HMI control interface
• SCADA with Normal Grade computer
• SCADA with Industrial Grade computer
HYDRO STRETCH TEST EQUIPMENT FOR CNG GAS CYLINDER ( VEHICLE CYLINDERS )
Model No. HST-350 HPU- SCADA
• No of test cylinder : 1
• Max test pressure : 300 Bar
• Equipment capacity : 350 Bar
• Expansion measurement : Automatic
• Interface : SCADA- IPC/ SCADA NPC / HMI ( customer selection )
• Operation : PLC
• Sequence : Semi Auto
• Power : 2 HP
VOLUMETRIC EXPANSION TEST EQUIPMENT FOR CNG GAS CYLINDER ( FOR CASCADES )
Model No. HST-600 HPU- SCADA
• No of test cylinder : 1
• Max test pressure : 550 Bar
• Equipment capacity : 600 Bar
• Expansion measurement : Automatic
• Interface : SCADA- IPC / SCADA NPC / HMI ( customer selection )
• Operation : PLC
• Sequence : Semi Auto
• Power : 2 HP
EQUIPMENT RELATED INFORMATION
Clamping Vice for Adaptor fixing with jacket Lid ( Customer Scope )

Water Jackets with built in safety system

Pre-filling system for water jacket and test cylinder :

High Pressure Generation System
Hydraulic power pack driven high pressure generation system with required controls is a highly reliable and maintenance free system today.
Power requirement will be 2 HP
Max water pressure will be 350 bar / 600 Bar depending on model selection

Instrumentation controls
High precision, Imported, pressure transmitters for accurate pressure feedback

High precision, Digital scale for water volume measurement feedback

Auto cutoff valves for control of test parameters

Water filtration system for enhanced performance of water components

Automation & Electricals :

• Measurement of water volume before applying test pressure, after giving full value of set pressure as well as after releasing the test pressure.
• PLC system for controlling the operational sequence .Pressure Transmitter to record the pressure value.
• HMI for operation and viewing the test results for HMI machines ( HMI not required for SCADA based machines )
• Electric control panel with branded relays, contactors , signal conditioners, signal isolators and other required hardware
• Control panel with tube light, extra plug sockets, cooling fan, filters etc will be available by default.
• Schneider or equivalent brand high end PLC hardware with some spare IO’s will be designed and made available

Computer Registration System / SCADA-DAQ System :

• Test results will be displayed on computer screen and test reports will be saved in computer hard disk at a predefined location in an excel or pdf format as per customers selection
• Customized Test reports with company name, logo , serial no, description etc will be designed for issuing test certificate with unique auto generated serial no to issue the test certificate to end customer.
• Optional Utilities such as data management software system as well as Management Reporting Module will be made available to customer at an additional cost as and when needed.
• Normal PC or IPC with IP65 protection will be available as per customer’s selection and shall be quoted separately
• Printer shall be quoted separately

DISPLAY AND RECORDS :

• Maximum expansion volume of cylinder under test
• Residual expansion volume of cylinder under test
• Max pressure applied
• Percentage of stretch
• Test medium used
• Mode of failure
• Passed or Failed
CUSTOMER SCOPE :
• Overhead Water storage Tank to conduct the test, if required
• Initial Hydraulic oil filling at the time of commissioning.
• Power supply with stabilizer / UPS for computer system
• Utility such as air, water, electricity, earthing etc

PROCEDURE :

Put the cylinder into a water jacket and pressurize the cylinder by high pressure pump; it will slowly dwell with the rise of pressure inside cylinder.
With expansion of main cylinder under pressure , the cylinder squeezes some water from water jacket into the measuring cup, and the water in the measuring cup now is the testing cylinder volume deformation, and then the water measurement data is transferred to PLC by water collection system;
The cylinder elastic deformation disappears after pressure releasing, then the water flows back from measuring cup to water jacket.
However, the remaining water in the measuring cup is still more than that before pressurizing the cylinder and the extra water volume is the testing cylinder volume residual deformation, and this measurement is transferred to computer through water collection system;
The gas cylinder permanent or residual deformation rate is the ratio of the total expansion- elastic expansion/ Total expansion
CALCULATIONS :
The Temperature during the test shall remain constant and hence density of water will also remain unchanged.

The following readings will be taken by computer.

1. Volume/ weight of water in the measuring cup before the test pressure has been applied : V1
2. Volume/ weight of water in the measuring cup after the test pressure has been applied for at least 30 sec : V2
3. Volume/ weight of water in the measuring cup after the test pressure has been released : V3

Total volumetric expansion = V2-V1
Permanent Expansion = V3-V1
Percentage deformation= ( permanent expansion/ total expansion ) x 100

This percentage deformation should be within the allowable range of percentage for cylinder to have passed the test.

The allowable percentage will differ from product to product and application and the data will have to be collected from statutory regulatory authorities concerned.
( for normal applications, it is between 6 % to 9 % )

OPTION-2
HYDRO STRETCH TEST BY WATER JACKET METHOD AS PER IS : 5844
( Air Driven Pressure Pump System )

To reduce the capital investment, this option also is available
In this option, Air driven pump will be used for building up high water pressure.
Air driven high pressure pump for high pressure built up.
Max water pressure will be 450 bar / 600 Bar depending on model selection

( A suitable air compressor, air receiver tank, air dryer and other required accessories for providing dry and lubricated air to drive the pump shall be arranged by customer )

( water line with proper filter and line pressure of at least 2 bar to be arranged by customer to nearby point of machine connection )
TECHNICAL DIFFERENCE BETWEEN AIR DRIVEN PUMP & HYDRAULIC POWER PACK DRIVEN PUMP

AIR DRIVEN PUMP V/S INTENSIFIER :

Time and air consumption :

The normal drive air pressure available in shop will be 5 to 6 bar and to reach the required output pressure of 300 bar will need intensification ratio of 60. This means plunder area is 60 times smaller than drive piston area. This will lead to a very small amount of discharge volume. The pressure rising time will be high and this leads to continuous consumption of drive air

power pack driven system will have intensification ratio of 3 to 4 only leading to high discharge volume available per stroke

Air Quality :

Air compressor, Air Receiver, Air cooler, Air Dryer, Air Filter , lubricator and regulator—needs to be installed and maintained in order to have a trouble free working of air driven pump.

Hydraulic power pack driven intensifier has oil cylinder on one part which is self lubricated hence maintenance free operation is ensured. No need of installing additional items to conduct the test. So independent of other ancilliaries and no additional investment on such items required in this case.

PRE-FILLING SYSTEM :

Some equipment supplier expect customer to provide minimum 1 bar pressure water line. This wording removes many items from their scope of supply

1. Prefilling pump
2. Suction strainer
3. Outlet water filters- cartridge type
4. Safety bypass valve for pump
5. Water tank
6. Water tank drain valve
7. Water level control switch
8. Water tank float switch
9. Intermediate pipings

This helps to reduce the size of fabrication panel and associated cost

In powerpack driven system , all the above items are part of equipment supply
AIR DRIVEN PUMP MACHINE :

CUSTOMER NEEDS TO INVEST FOR

• Air Compressor
• Refrigerant Type Air Dryer
• Air Lubricator
• High Running cost for producing air as efficiency of compressor is almost 60 %
• Low Production Rate
• Arrangement of water pre-filling system with proper filtration arrangement
POWER PACK DRIVEN INTENSIFIER TYPE MACHINE :

• The customer will need to provide water tapping line and Quality electric power line to the machine point
• All Other required items are included in the machine
• No additional investment needed to drive the high pressure pump
• Production rate is high
• Running / Operational cost is low

VALVING MACHINE FOR CNG GAS CYLINDER 

CNG Valve fitting.

   

Requirement
• valve fitting.
• Cylinder Diameter- 232 mm to 406mm.
• Cylinder length- 500mm to 2200mm.
• Torque range : 50 N-m to 350 N-m
• Accuracy for torquing +/- 1 kgf-m
• Power requirement : 1.5 to 2 HP / 1.5 KW
• Spindle Speed : 22 Rpm ( Appx )
Consideration:
• Clamping by hydraulic cylinder
• Hydraulic Motor for providing torque value
• Other operation manual.
• Control panel (relay base with small PLC + HMI )
Mechanical construction:
• Base frame.
• Bracket for hydraulic motor.
• Hydraulic cylinder holding brackets.
• Horizontal 2 mt free roller conveyor segment for cylinder loading.
Hydraulic system :
• Hydraulic power pack with oil tank, level indicator, filter, breather, suction strainer, pressure transmitter
• Hydraulic Power pack unit with Valves and Manifold
• Hydraulic motor for torque application
Electrical control panel:
• Panel – Duly powder coated control panel with operating pendent.
• PLC + HMI for display of torque values and automatically cutoff the system when torque value is reached
• SMPS 24 volts
• Schneider/ Equivalent switch gear components
• Job presence sensor / limit switch.
• Torque / pressure transducer with controller for torque value.
Operation Sequence : Opening of valves
• Load cylinder on conveyor segment manually.
• Push cylinder to butt with stopper.
• Press clamping cylinder push button.
• Clamping cylinder will clamp CNG cylinder.
• Set the valve and valve gripping tool for valve opening function
• Display of Torque Value on display unit
• Clamping cylinder de clamp.
• Push cylinder back manually.
• Unload cylinder & system ready for next cycle.

Operation Sequence : Mounting of valves
• Load cylinder on conveyor segment manually.
• Push cylinder to butt with stopper.
• Press clamping cylinder push button.
• Clamping cylinder will clamp CNG cylinder.
• Set the valve and valve gripping tool for valve tightening function
• Display of Torque Value on display unit
• Clamping cylinder de clamp.
• Push cylinder back manually.
• Unload cylinder & system ready for next cycle.

CONVEYOR ARRANGEMENT WITH TILT STATION AT BOTH END 

     

EXTERNAL SHOT BLAST MACHINE 

EXTERNAL SHOT BLAST MACHINE FOR CNG GAS CYLINDER RETEST SHOP
Features of Machine:

• It is a fully auto operated machine through PLC control, hence only one operator required for all
operations.
• Main blasting cabinet is fully lined with abrasive wear resistance alloy steel liners to protect from wear.
• Loading & unloading of cylinder is shifted form main blasting line, to prevent the shot leakages from entry and exit side, because of this we have provided separate loading & Unloading cabinets with screw conveyor along with separate drive arrangement.
• The skew rollers are specially designed with both end supported and positive drive arrangement by bevel gears thoroughly.
• The skew shafts in the blasting chamber are covered with hardened sleeve to prevent the shaft wear.
• Variable speed drive provided to regularize the skew conveyor speed for blasting quality of various sizes cylinder.
• One number RLM type bare wheels with 15 HP drive unit each are fitted on 16 mm thick top plate of the blasting cabinet to improve the blasting coverage & easy maintenance.
• Pneumatically operated loading & unloading arrangements are provided with auto operation.
• Separately diabolla roller conveyors with drive unit are provided for loading & unloading arrangements.
• All bearing are fitted at outside of the blasting cabinet for easy maintenance.
• Shot storage hopper with air wash for cleaning of the shots.

CONSTRUCTION DETAILS:

• Main Body made out of 8 mm thick MS plate in welded construction with structural reinforcing. Main body including roof will be fully lined in Manganese steel liner of size 6mm and 10 mm thick for to protect from wear and tear by high velocity shots. When these liners worn out, the particular pieces are to be replaced. A breather box shall be provided at the top of the main body to enter fresh air in side when other end air shall sucked by the blower fan through dust collector.

• One nos. of fabricated inspection doors shall be provided with proper reinforcement and complete wear resisting lining, mounted bucket elevator side of machine. A limit switch is provided on the top of the door for safety purpose, until and unless any one of the door shall completely closed, any of the turbine will not be operate.

• Turbine unit Ø 385 mm x 63.5 mm wide RLM type, dynamic balanced Blast wheel with self-lock blades duly balance individually, Spindle assembly, manganese steel guard liners. Turbine assembly shall be driven by 15 HP drive unit through V belts. The shot flow capacity of each turbine shall be 160 Kg / min. at velocity 50 meter./sec. The mounting of each turbine shall be made out of thick plate and such a way that do not penetrate the shot flow to another one, hence it will work in safe side for long time.

• Two nos. of Screw conveyor shaft assembly 6” LH & RH with 1 HP drive unit for screw for shot recycling at the bottom of the main blasting chamber. These screw conveyors feed the shots to bottom of the bucket elevator. These shots are elevated to the desire height with the help of buckets which mounted on the thick rubber belt. Bucket elevator assembly with 4” wide rubber belt with fabricated buckets, top & bottom pulley assembly Bucket elevator driven by 1 HP motor. Tensioning arrangement of elevator belt shall be provided at the top of the elevator, hence to adjust the belt tension as required and to control the slippage of the belt. The dynamic air separator system continuously segregates the broken shots and dust particles from the shots and fresh washed shots shall transfer through shot distribution screw conveyor to the storage hopper for recirculation purpose. These fresh shots shall be fed to the each turbine units through separate soundabrator shot control valve assembly operated by pneumatic cylinder and electric operated solenoid valve. The controlled shots thrown through turbine by centrifugal force on the job at very high velocity around 50 meter/ sec. of speed and after striking on the job, it remove the scale particles from the job surface and fall down by gravity in the main body along with the shots passes through the perforated grill plates. This mix up shall be again and again recycled and separates it in shot storage hopper of capacity 500 kg capacity with distribution screw conveyor.

• A filter cartridge type dust collector shall be provided to suck the dust particles and to separate the broken shots from the shot air wash system during the blasting operation. A number of filter cartridges are provided inside the close fabricated leak proof casing of dust collector. The heavy particles of dust settled in the bottom hopper of the dust collectors and fine dust shall be collected around these filter cartridges. Air jets shall be provided for filter cartridges cleaning purpose. All filter cartridges shall be cleaned at a time periodically with the help of timer and clean air discharge through the blower fan to the atmosphere.

• All drive guards shall of designed such a way to fit and dismantle easily when for maintenance propose. A service platform shall be provided to maintain the bucket elevator assembly and shot storage hopper. Suitable ladder and safety railing guard provides all over service platform.

• Programmable logic controlled electric panel with auto mode, manual mode and interlocking with inspection door etc.

TECHNICAL SPECIFIATION FOR EXTERNAL SHOT BLASTING MACHINE FOR LARGE CYLINDER RETESTING

• Size of Cylinder :
Diameter : 232 mm to 406 mm
Length : 750 mm to 2000 mm

• Production Rate :
25 Cylinder per hr. Above dia 267 mm cylinders will be cleaned in two pass.

• Space required for Machine :
7500 x 3000 x 4600 mm Ht.

• Machine main body size :
3200 mm length x 650 wide x 2100 mm Ht. With entry & exit vestibule

• Nos. of curtain in Vestibule :
3 nos. curtain in each Vestibule

• Skew roller conveyor :
Skew roller Ø150 x 330 length
Conveyor length 7450 mm
Manganese steel skew rollers inside of body.
CI casted skew rollers for loading & unloading
Skew roller pitch 250 mm
1 HP drive.
Conveyor speed 660 mm.

• Loading Arrangement :
Inline feeding.

• Loading cabin :
2100 mm length x 750 mm x 1500 mm Ht.

• Unloading Arrangement :
Inline.

• Unloading cabin :
2100 mm length x 750 mm x 1500 mm Ht.

• Screw Conveyor (Main Body) :
LH Side Ø 150 mm x 4350 mm length
RH Side Ø 150 mm x 2900 mm length
RPM 95
Drive 1 HP.

• Bucket Elevator :
Size 600 mm x 300 mm x 5600 mm Ht.
RPM 95
Drive 1HP

• Shot Storage hopper. :
Capacity 500 kg.
With double air wash.

• Shot Discharged valve. :
Pneumatically operated. Soundabrator valve

• Turbine Unit. : 1 No.
Size Ø385 x 63.5 mm wide RLM Type
Blade self-locking
Turbine Guard Liners in Manganese steel
Drive 15 HP for each turbine
Shot flow rate 160 kgs./ min./ turbine

• Dust collector unit :
Reverse pulse jet type
Dust collector type : Cartridge type plated bags
Air to be filtered : Air with flashes/ dust
Air required for machine. : 20 cfm @ 5 to 5.5 Kg/cm2 filtered and regulated (Not in our scope)
Design Temp. : 60°C Max.
Cartridge Cleaning System : Reverse Pulsejet
Filtration Area : 12 M²
Media : Polyester plated BIA Class C
Cartridge size : Ø 327 x 985 mm long. (6M² – 2 Nos. of filter cartridge)
Dust Loading : 20 mg/m³
Filtration efficiency : 3 micron up to 99.9%
Crude Air inlet : Ø 200 mm
Clean Air Outlet : Ø 200 mm
Compressed air requirement : 12 NM³/Hr. @ pressure 5 bar.
Solenoid Valves : 1 ½” size 24 V DC – 2 Nos.
Timer Controller : Solid State Digital sequential timer controller 24V DC.
Discharge of Dust : Rotary air lock valve with 0.5 HP geared motor.
Timer : Sequential timer.
Fabrication Construction : Casing in M.S. sheet 2.5 mm thick and leg Support 4 mm thick M.S.
Plate with proper reinforcement.
Size of Dust collector : 900 x 1200 x 3200 mm Ht.
Exhaust Blower. : Direct mounted type.
Type : Centrifugal
Pressure : 250 Nm WC.
Type of Impeller : Straight
Blower speed : 2300 RPM
Suitable for Drive : 5 HP, 1440 RPM
Orientation : Vertical upward

• Total HP required : 24 HP.

• Shot Size :
S-180 (Not in our scope)

• Painting :
The machine will be painted in Opline green shed (mat finish)

SCOPE OF SUPPLY:
External Shot Blasting Machine for large Cylinder with single turbine for retesting line.

Main machine will be consisting of-
• Main Body made out of 8 mm thick MS plate in welded construction with structural reinforcing. Main body including roof will be fully lined in Manganese steel liner of 10 mm and 6 mm thick. The main body will coupled with entry & exit vestibules made out of 8 mm thick MS plates with three rubber curtains.

• Loading & unloading cabin made out of 4 mm thick MS plates in welded construction with structural reinforcing.

• Turbine unit Ø 385 mm x 63.5 mm wide RLM type Blast wheel with self-lock blades, Spindle assembly, Ni-hard steel guard liners, & 15 HP drive unit.

• Skew roller conveyor (manganese steel rollers inside of main body, MS rollers on loading & unloading conveyor with 1 HP drive unit.

• Screw conveyor shaft assembly 6” LH & RH with 1 HP drive unit for each screw.

• Bucket elevator assembly with 4” wide rubber belt with fabricated buckets, top & bottom pulley assembly Bucket elevator driven by 1 HP motor.

• Shot storage hopper 500 kg capacity with rotary screen assembly, & pneumatic operated shot discharged Soundabrator type valves.

• Drive guards with easy fittings.

Dust collector unit Reverse Pulse jet type consisting of-

• Main body casing made out of 2.5 mm thick MS plates in welded construction with suitable structural reinforcement.
• Pleated type filter Cartridges.
• Exhaust blower fan assembly with 7.5 HP motor.
• Interconnecting ducting up to 5 meter.

Electrical control panel consisting of-

• PLC Mitsubishi / Delta make
• All electrical switchgears Siemens make.
• All control cables Finolex make.
• Exhaust fan will be provided for cooling.

Bought out material details

• All pneumatic cylinders, solenoid vales and pneumatic fitting are of Electro pneumatic / SMC / Festo make.
• All electrical motor are Siemens / Crompton greaves make.
• All Geared motors are Premier / Bonfiglioli make.

INTERNAL DRYING BY HOT AIR 

    
• After hydro-test, the moist internal surface of gas cylinder needs to be dried.
• This equipment is designed for the removal of residual moisture by applying hot air inside the cylinder to dry the inside of cylinder surface.
• Electrical heating and Compressed Air Blowing combination is used to generate dry air
• Cylinder size : OD 219 to 400 mm , Height : 600 -2000 mm
• Body 18 Gage MS sheet, bolting, welding
• Insulation 75mm Glass wool Heavy duty
• Panel Digital Controller with timer, M.C.B
• Electric Heating by Heater 3 phase 415V AC

 

1″ NPT Male Thread Gauges