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General Information:
General Information :
Based on the burst pressure nominal hoop stresses of a cylinder at burst pressure conditions are
calculated
One cylinder from every manufactured lot of 403 and below should test for measuring burst
pressure and nominal hoop stresses. Generally the cylinder tested for volumetric expansion test
can be used for this purpose. In this test, cylinders are subjected to continuous hydro-static
internal pressure till it bursts. The internal pressure of cylinder at which it bursts is noted and
recorded as burst pressure. Based on this burst pressure nominal hoop stresses are calculated
using below formula
fb=(Pb ×Di)/2t
fb-nominal hoop stress at which destruction occurs
Pb-Internal hydrostatic pressure at which cylinder bursts in MPa;
Di -Nominal original internal diameter of the cylinder in mm
t-minimum agreed finishing thickness of the cylinder in mm.
Test Parameters :
Max Test pressure : 160 Bar / 250 Bar
No of test cylinders : 01 Nos
Test Temperature : Ambient
Max cyl size :
Min cyl size :
Test duration : 2-3 min appx
Type of test : burst pressure test
Main Equipment Consists of :
Burst Test Chamber
Pressurizing Unit
Local control Unit with PLC and HMI and electrical control panel.
Centralized SCADA for Data Acquisition, report generation and trend display over computer
pc
( Common for all test Lab equipment mentioned in the proposal )
Ancillary Equipment / Items required :
Cage to contain cylinder during testing
Clear Gap of at least 1 Mtr on all sides of test equipment for ease in maintenance
Low Pressure Air compressor for utility air
IS 3196 PART-3
One cylinder from every manufactured lot of 403 and below should undergo hydro-static stretch
test
Standard allows permanent volumetric expansion of 1/20000 the total cylinder capacity.
Volumetric expansion (VE) : Should be greater or equal to 20 % ( for TS less than or equal to
410 Mpa )
Technology Used :
Operational Interface :
• 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
In SCADA 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
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.
This value should be within 1/5000 of the original volume of the cylinder
OPTION-2
VOLUMETRIC EXPANSION TEST METHOD BY WATER JACKET METHOD AS PER IS :
5844
( Air Driven Pressure Pump System )
( water line with proper filter and line pressure of at least 2 bar to be arranged by customer to
nearby point of machine connection )
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 ancillaries 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
• Refrigerent 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
SYSTEM DESCRIPTION
Test setup for ambient cycle test consists of testing 2 test cylinders . The system will have a
pressurizing unit for achieving required peak and base pressure and to detect failures when this
occurs. Local control panels communicate with a central PC, which provides the data logging
and reporting capability.
Description of Operation:
This section describes operation of system to illustrate ease of use, and to show the interaction of
the different components within the system:
• From PC, operator sets the test parameters including test ID, cylinder information, test
conditions and no of cycles to be tested.
• Operator installs specimen, fills it with tap water, connects it to pressurizing unit and enables
testing from the local control panel. As pressure starts to build up, air vent should be manually
opened until air is purged from specimen. Test may be interrupted to attend to minor leaks,
adjustments or until both specimens are ready to start.
• During test, the local control system automatically monitors and logs test data in real-time.
Relevant information is displayed real-time on the HMI display and is sent to the PC for data
logging and reporting. In case of PC failure or unavailability, data is stored locally until PC is re-
connected.
• At termination of test, reports are displayed on PC.
Features
Below are some important features of the long term testing system:
• Long-term stability.
• Data is saved on local unit until accessed by PC
• Handshake mode, central unit constantly monitors health of local units.
• Pressure sensors provided to match testing ranges.
Main body.
Seamless pipe rollers 2 nos,
Screw conveyor.
bucket elevator.
shot separator.
shot storage hopper.
shot control valve.
blasting unit.
dust collector.
interconnecting ducting
electrical control panel.
BLASTING CHAMBER:
The main blasting chamber is fabricated out of 8 mm thick MS plate and necessary structural
supports are provided to give it a adequate strength. The inside of the chamber is lined with
abrasive resistance Mn. Steel lining 8 mm thick which protect the body plates from wear. The
chamber is connected to dust collector. A grill is also provided at the bottom of chamber which
prevents any large particles or jobs falling on to screw conveyor.
SCREW CONVEYOR:
This is fitted at the bottom of the blasting chamber to carry the shots and fed to the bucket
elevator. It is made out from 6 mm thick MS plate with proper helix. One edge of the screw
conveyor flights are hard face to avoid fast wearing. The screw conveyor end shaft both are fitted
in self aligned bearings which are mounted outside of the body.
BUCKET ELEVATOR:
The bucket elevator is fitted on the main body to lift the shots from bottom and fed to shot
storage hopper. Crown pulley is mounted on the top of bucket elevator and other pulley to
bottom to drive the belt assembly with buckets. Tension screws are provided to give tension to
belt. Bucket elevator belt is driven through bonfingly Italy make geared motor with chain and
sprocket.
ABRASIVE SEPARATOR:
The abrasive separator shall consist of wind shifting arrangement working on the principals of
dynamic deflection of grains. The bucket elevator shall discharge shots, dust and sand into the
wind shifting arrangement through a screw conveyor, which removes large size particles. The
material shall be allowed to fall by gravity. The shots shall be arranged to fall in several cascades
so as to increase the contact through at least 2 baffles. The arrangement shall insure a full length
even thickness curtain of abrasive presented to the Air washing flow and even thickness curtain
of abrasive curtain. This shell is connected to the dust extraction system to ensure collection of
thoroughly cleaned shots into storage hopper. The arrangement shall be provided to prevent
small abrasive from being carried out into dust collector.
SHOT CONTROL VALVE ASSEMBLY:
The sound aerator valves are provided at the top of the turbine unit with feed spout and feed
funnel to control the flow rate of shots and cut the shot supply when the impellers are stopped.
These valves are to be operated by leavers manually or pneumatically.
SHOT BLASTING TURBINE:
The shot blasting turbines are the main part of the machine, which impinges shots on the
components generally at right angle on the areas to be blast cleaned. There is one unit fitted on
the top of main body. Which is the center line with the tables. It consists of a bare wheel, which
is hardened and dynamically balanced. It is mounted on a shaft, which rotates in a bearing
housing with taper roller bearings. The bare wheel assembly is enclosed in a fabricated housing
with wear resistance Mn. Steel liners. Of shot is adjustable In 360 degree with the help of control
cage. The complete list of liners and other part is illustrated in the enclosed drawing .
DUST COLLECTOR :
The efficiency of the blast cleaning on the proper control of dust in the main chamber and steel
shot. If not controlled they may prove even health hazardous. Hence an efficient dust collector is
always provide with machine. The dust collector is made of steel properly folded so that it can be
easily disassembled. A plate fitted with 48 tube is fitted inside the body for filling of dust
collector bags. the other end of the bags is hooked to the special hooks made out of steel bar. The
hooks can swing in either direction by shaking mechanism. This is useful to shake out the dust
from bags. A centrifugal balanced blower is mounted beside of the dust collector body. It sucks
the Air from dust collector through bags. The dust sticks to the bags and clean Air is discharged.
It is very essential to shake the bags to avoid clogging after every 8 hrs of working. Also check
the condition of the filter bags every month replace the worn bags.
INTERCONNECTING DUCTING:
Interconnecting ducting between machine and dust collector is provided. Through this dust is
sucked from shot separator and machine body. It has got a baffled adjustment to control the
suction. Rubber sheet gaskets properly seal the joints of the ducting.
ELECTRICAL CONTROL PANEL:
The electrical control panel is equipped with contactors, overload relays and MCB for each drive
motor. Interlocking is provided to maintain sequence of operation and safety. Control panel is
made suitable for 440 V, 50 cycle. All electrical parts used L & T make, Telemechanic or
Siemens make.
All cylinders are subjected to hydrostatic test to check leaks if any, this is carried out at test
pressure conditions and the pressure is applied for 30 seconds to check any pressure drop or
leaks from body and weld joints
Every cylinder produced in a manufacturing location should undergo hydrostatic test. In this test,
cylinders are subjected to hydrostatic test pressure of 25 kgf /cm2 and retain the pressure up to
30 seconds to check any pressure drop. Once the cylinder surface is dried, they are checked for
leaks and pressure drop. If there is any pressure drop or any visible external leaks on cylinder
body or on welds, the cylinder is disqualified for usage
Test Parameters : ( IS 3196-1: 2006 )
• Max Test pressure : 25 Bar
• No of test cylinders : 06 Nos ( Can be offered for 8 Nos & 10 Nos also )
• Test Temperature : Ambient
• Max cyl size :
• Min cyl size :
• Holding Time : 30 Sec
• Type of test : Hydro Proof Test
Main Equipment Consists of :
• Test Rig for Mounting of cylinders
• Tilting and clamping system
• Pressurizing Unit
• Water Recirculation System
• Local control Unit with PLC / HMI and electrical control panel
Ancillary Equipment / Items required :
• Low Pressure Air compressor for air
Display and Records :
• Proof Water Test Pressure
• Holding Time
• Pressure Drop, if any
• Test Medium Used
• Pressure v/s time graph ( in Scada Machines only )
EQUIPMENT RELATED INFORMATION :
SYSTEM DESCRIPTION
Test setup for hydrostatic proof testing consists of a Cylinder mounting arrangement to test six to
ten cylinders at a time and a pressurizing unit to provide required hydro test pressure . A local
control panel is provided to display the status and test data . Local control panel with integral
PLC and HMI system for local operation.
Cylinder Installation :
For ease in loading of cylinder, the frame is tilted by push button operation. After loading of
cylinder and air release tubes , the cylinders are made vertical by push button operation. After
reaching in to vertical orientation , cylinders are clamped by push buttons
Once service valve is fitted on LPG Cylinder every cylinder has to undergo pneumatic leak test.
Under this test, pneumatic pressure of 1180 kPa is applied to cylinder to verify any leaks from
cylinder body or weld leaks
Verification of metal properties like yield strength, tensile strength and percentage elongation of
cylinder parent metal.
Acceptance Test :
For every batch of 203 cylinders or less produced in a manufacturing location, one cylinder must
undergo the acceptance test.
Radiographic examination :
Radiographic examination is intended to check weld quality and the weld defects in a cylinder
during manufacturing process the examination is conducted on weld overlap to check weld
defects
AAKASH HYDRAULICS
New Survey No 1594/2, Old Survey No : 132/2 , Near Gopnath Society, SH-4, Bakrol Dholka
Road, Village: Kasindra-382210, Ta Daskroi, Dist : Ahmedabad