Procedure for Cylinder Testing
1. Cylinder receiving and labelling on cylinder
Unload the cylinder from the vehicle.
Do not drop the cylinder or handle by valve.
Do not drag the cylinder along the ground and do not roll of storage.
Verify the cylinder nomenclature like cylinder previous inspection & testing certificate and
note down the serial number of the cylinder and name of the customer or vehicle
registration number.
2. Degassing and valve opening from the cylinder (Through Atmospheric venting method) IS:
8451
Carry the cylinder towards the degassing platform with the help of cylinder trolley.
Place the cylinder at degassing platform and clamp it inside the cylinder holding clamp
properly.
Now connect the cylinder valve with degassing valve which is already connected with cold
flaring vent.
Now start releasing the gas by opening the valve of the cylinder.
After the complete gas released from the cylinder then open the cylinder valve with the help
of slide wrench.
Now mark the label "EMPTY" on the cylinder shoulder or neck.
3. Visual inspection and internal cleaning of cylinder IS: 8451
In that process we examine the cylinder from outer surface and inside the cylinder.
In this process we observe that the outer surface of the cylinder is free from rust, crack,
dent, bulge and any kind of cut or weld on the surface of cylinder.
Then we check the threads of the cylinder neck rather it is free from step, crack or any kind
of damage.
Now we put some amount of chemical that is TCE (Tetra Chloride Ethane) inside the
cylinder with some iron balls or wired brush and rotate the cylinder for 4 to 5 minutes. It
helps to clean the cylinder from inside if any kind of rust is deposited on the inside wall of
the cylinder.
Now we remove the chemical from the cylinder and check inside the cylinder with the help
of BOROSCOPE CAMERA for any damage inside wall of the cylinder.
4. Weighting of the cylinder IS: 8451
After visual inspection & internal cleaning of cylinder we check the weight of the cylinder.
Place the cylinder on the weighting machine horizontally and weight the cylinder weight.
Note down the cylinder weight which we get after weighting and calculate with Tear weight
of the cylinder which is marking on the cylinder shoulder or neck.
If we observed any kind of weight loss, then calculate the weight loss Percentage.
If the weight loss percentage of the cylinder is more than 5% than the cylinder is rejected
due to weight loss.
5. Hydro Static Stretch Test IS: 5844
In that process first of all fill the cylinder with water and clamp it with valve which is
connected with water jacket cover plate.
Lift up the cylinder with the crane and place it inside the water jacket which is already filled
with water
Close the water jacket properly air tight and connect the pipes which is connected with
water source and graduated tube.
Now start the water flow inside the water jacket which is shown in graduated tube. Set the
initial reading of the water inside the graduated tube (R1). Now start the pump which starts
the flow of water with pressure inside the cylinder. Then open the pressure valve which flow
the water from inside the cylinder and make it free from air.
Now close the valve and maintain the pressure inside the cylinder. So that the water start
rising inside the graduated tube. Put the testing pressure inside the cylinder and stop it.
Maintain that pressure inside the cylinder for 30 Seconds. Note down the reading from
graduated tube (R2) and check it's drop or not for 30 seconds.
Then after release the pressure from the cylinder and note down the reading from
graduated tube (R3).
Calculate the stretch percentage of cylinder with the help of noted reading R1, R2, R3 by
using relation #3-R1 X 100. If the stretch percentage is more than R2-R1 10% then the
cylinder is rejected.
6. Decanting & hot air dryer IS: 8451
After stretch test lift the cylinder from the water jacket and open the valve.
After opening the valve empty the water from the cylinder.
Then blow the hot air inside the cylinder at 65 @C apx. For 10 to 15 Minutes.
7. Ultrasonic flaw detector & thickness testing IS: 8451
After drying the cylinder put the cylinder on the automatic facility for ultrasonic flaw
detector.
In that testing we check the cylinder for linear damages or cracks of the wall.
Then we check the thickness of cylinder wall which should not be less than 6.3 mm.
8. Punching & marking on cylinder IS: 8451
After ultrasonic test provide punch & marking on the cylinder.
Mark the symbol or stamp of the cylinder testing station and date of test done on the neck
or shoulder of the cylinder.
9. Valve fitting IS: 3224
Now fix the valve having a ring which is mounted between valve and cylinder neck.
On the ring mark the cylinder number and next due month & year for test.
Test the valve for leakage.
10. Painting of cylinder IS: 4379
Now paint the cylinder with the help of spray painting machine or manually by brush.
Paint the body of cylinder with white paint and neck or shoulder of the cylinder with red
paint.
11. Final dispatch of cylinder
After all tests the cylinder is ready to be dispatch.
Statutory certificate must be issued describing the cylinder details/condition for the client.
Precautions during test
There should not be any ignition sources near vent pipe.
Having a portable fire extinguisher present at the degassing location.
Pasted signs such as "NO SMOKING" and "FLAMMABLE GAS".
Explosive meter for flammable gases to indicate the gas level present in the atmosphere
while degassing
Do not drop the cylinder or handle by valve.
Do not drag the cylinder along ground and do not roll of storage.