LPG EQUIPMENT-ST-HR Segregation

LPG Equipment and Segregation
Of ST/HR/ defective cylinders

LPG cylinder
ON LINE TESTING - AT LERC - 2 CYLS OF

SAME BATCH OF ONLY 1 PARTY/ PLANT IN 1
QTR COVERING ALL PARTIES IN 1 YEAR
Min 67 Microns- paint thickness
Tare wt difference not more than 50 gram
Torque145+/-15 LB-FT : 20 +/- 2 kgm
Standard markings
“O” formation in foot ring instead of “J”
LPG cylinder
DESIGN/MANUFACTURE/FILLING/
CHECKING/HANDLING/REPAIR - AS
PER GAS CYLINDER RULES 1981
DESIGN AS PER IS:3196 - PART I - 1992
STEEL AS PER IS-6240, 2.4 +/-
0.1 X 2480 X 1240 mm
Hydrostatic Test
Pneumatic Test
Heat Treatment, shot blasting, painting,
valve fixing
Cylinders- Specifications
Cylinder Manufacture  Cylinders testing
 Manufactured as per Gas cylinder Rules  after 10 years from date of
1981. manufacturing first time
 Welded low carbon steel cylinders of water  subsequently every 5
capacity exceeding 5 lit of water capacity & years.
up to 250 lit w/c to be manufactured as per  The cylinders acceptabilty
IS 3196: 2006 (Latest). for use as per IS 13258 in
 The cylinders are manufactured from steel Plant & during testing.
as IS 6240 having minimum percentage  Cylinders reconditioning
elongation of steel as 25. as per IS 13258
 LPG Cylinders are to be approved by Chief  Hot work permitted only
Controller of explosives and Bureau of for replacement of Stay
Indian Standards. plate & Footring.
 Every LPG Cylinder Manufacturer to obtain license from Bureau

of Indian Standards after obtaining drawing approval from Chief
Controller of explosives.
Self closing LPG Valves
DESIGN - IS 8737 - 1995
Cylinder filled in 60 sec with
differential pr of 2 kg/sq cm
Torque 20+/-2 KG-M
Safety cap to withstand 25 kg/sq cm
Provide gas tight seal in closed
position & to prevent the contents
leaking and in open position to allow
filling, discharge.
Self Closing valves
ON LINE TEST SAMPLE – Four valves of

same batch of only one
manufacturer per plant in one
quarter covering all parties in one
year
Warranty 2 YEARS
ULTRASONIC VALVE CLEANING
EQUIPMENT with 3 chambers, SKO
with or without frequency.
What is ST of cylinders ?
All cylinders used for filling LPG are

required to be tested periodically to
ensure fitness of the cylinders for further
service. First re-testing is required to be
done after 10 years ( after June 2000)
and subsequent re-testing after every 5
years interval. Such tests are to be
conducted by the CCOE approved
parties only.
What is a HR cylinder?
A cylinder with a broken VP ring,

bent stays, broken Foot ring or
damaged foot ring which
renders the cylinder
unserviceable.
Why ST/HR ?
Safety
Profitability/ Reduce cylinders out of
circulation
Improved appearance/packing
Achieve KRA/ MOU parameter
MAXIMUM 0.1 % of bottling
Statutory testing
PERIODICITY : 10/5 YEARS
1. Receipt of Cylinders
2. Depressurising
3. Recording details
(like Sr.No., Test Dates, Tare weight,
Manufacturer's name)
4. Valve Removal
Statutory testing
5. Degassing
6. External surface cleaning
7. Internal cleaning and internal
inspections
8. Visual Inspections of external surface
and bung threads by L-1 and L-9 plug
gauges
Statutory testing
9. Tare weight checking

10. Hydrostatic testing
11. Internal cleaning and drying
12. Valve fixing and Pneumatic
testing
Statutory testing
13. Painting :
One coat of primer : 15 microns
One coat of Signal red paint : 15

microns
Statutory testing
14. Punching of test date &

repairer’s identification mark
15. Colour coding for age profile
16. Certification and despatches.
Statutory testing-repairer
CCOE Licence
Factory Licence
Required facilities/ machinery
Rate around RS. 40/CYL
ST-Colour coding for age profile
Background ISI specification for Lettering Year of Year of re

colour shade Colour manufacture testing
Black Shade No. 521 White 2000 2010
Yellow Shade No. 355 Black 2001 2011
White Shade No. 127 Black 2002 2012
Sea Green Shade No. 217 Black 2003 2013
Dove Grey Shade No. 694 Black 2004 2014
Aircraft Blue Shade No. 108 white 2005 2015
Salmon Pink Shade No. 4423 Black 2006 2016
India Brown Shade No. 415 White 2007 2017

Satin Blue Shade No. 177 Black 2008 2018
Bus Green Shade No. 299 White 2009 2019
Hot repair
Visual inspection/ segregation as per
BIS-5845
Repairable/ Non-repairable
Priority : Both VP ring/ Foot ring
Only Foot ring
Only VP ring
Depressurising
Degassing
Hot repair
Cutting of Old VP ring/ foot ring

Welding of new VP ring/ foot ring
Checking Tare weight of cylinder
Cylinders having tare weight less than
95 % of original tare weight is to be
rejected as SCRAP
Heat treatment
Stress relieving and Normalizing
Hot repair
Hydrostatic test
Markings on the cylinder
Tare weight/ gross weight
manufacturer’s identification
Both in Bung and stay as the case may
be
Shot blasting /metalising- metallic Zinc
coating of 37 microns
Hot repair
Drying of internal surface
Fixing of valves and pneumatic test
– 10 kg/sq cm for 60 sec
Painting – One coat of Zinc chromate
primer and one coat of Signal red
paint- 37 + 30 microns
Stenciling-
Colour coding for age profile
Documentation
Hot repair- Repairer
Cylinder manufacturer, BIS

approval, CCOE approval,
Required machinery
Rate around RS. 300 /Cylinder
including transportation
Segregation of defective
cylinders
During receipt
1. Market return cylinders

2. Unserviceable cylinders
3. OMC cylinders
4. ST/HR cylinders
Market return cylinders
1. Under filled
2. Over filled
3. Bung leak cylinders
4. Valve leak/ O ring missing
Unserviceable cylinders/OMC
1. Burnt/Bulge/Dent cylinders
2. Spurious cylinders
3. Cylinders of other marketing
companies.
During filling
1. Valve leak cylinders

2. Bunk leak cylinders
3. O ring leak and O ring
missing cylinders
4. Under/Over filled cylinders
Packed LPG transportation
Objective :
1. To meet the customer
requirement in time
2. To deliver correct and quantity
and quality of cylinder in time.
3. Safe transportation
Modes of supply:
1. Delivered supply
2. Ex- MI supply
Periodicity of contract:
One year initially and

extendable for 2 more one year
periods:
Method of tendering :
Public tender :
To ensure competitive rates,
wide publicity and
transparency
Trucks requirement:
1. Caged trucks
2. To carry a standard qty of 306
domestic cylinders
3. Safety fittings
4. Age criteria of less than 11 years
as on date of tender
Method of selection
1. Preference to distributors
2. SC/ST reservation : 15 % for SC and
7.5 % for ST category
3. General category.
Rates
1. Minimum charges per cyl/FDZ
2. Plain charges within state-
paisa/cyl/RTKM
3. Plain charges outside state
4. Hilly rates
LPG Equipment Research Centre
Set up in 1990 as a joint Oil Industry
venture to carry out R & D in the field of
LPG Equipment in Bangalore
– Recognised –ISO 2001,BIS & DSIR
– Shared by PSU Oil Companies
– R&D on failsafe equipments
– Testing of LPG equipments for conformance
to quality and identifying cause of failure and
evolving solutions
Online Testing
– Samples of new equipment /
components (Cylinders, Valves,
Regulators and and consumables)
received from locations tested for
conformity to specifications
Failure Analysis
– Analysis of equipment failing in the
field to identify cause of failure and
solutions are provided.
Thank You

LPG EQUIPMENT-ST-HR Segregation

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LPG Equipment and Segregation

Of ST/HR/ defective cylinders

ON LINE TESTING - AT LERC - 2 CYLS OF

 Every LPG Cylinder Manufacturer to obtain license from Bureau

ON LINE TEST SAMPLE – Four valves of

All cylinders used for filling LPG are

A cylinder with a broken VP ring,

9. Tare weight checking

One coat of Signal red paint : 15

14. Punching of test date &

Background ISI specification for Lettering Year of Year of re

India Brown Shade No. 415 White 2007 2017

Cutting of Old VP ring/ foot ring

Cylinder manufacturer, BIS

1. Market return cylinders

1. Valve leak cylinders

One year initially and

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