Is 13258: 2014 anda are Indian Standard area rea aH a SH ere 5 Ferex a afte Fea aa ae aived aed art ged & fafeist— sora fd wa uerdish fateiet & preter ait Fda at ardent (Teen Fre ) Welded Low Carbon Steel Cylinders Exceeding 5 Litre Water Capacity for Low Pressure Liquefiable Gas — Requirements for Inspection and Reconditioning of Used LPG Cylinders (First Revision ) 1S 23,020,30;75.160.30 © Bis 2014 anda mae =p BUREAU OF INDIAN STANDARDS PEs we, 9 ameIgeMe awe HW, aE Peeefl-110002 MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG. NEW DELHI 10002 wwuctis.orgin www.standardsbis in January 2014 Price Group 5Gas Cylinders Sectional Committee, MED 16 FOREWORD ‘This Indian Standard (First Revision) was adopted by the Bureau of Indian Standards, ster the draft Finalized by the Gas Cylinders Sectional Committee had been approved by the Mechanical Engineering Division Courel “This Sandard was st published in 1991 and revision taken to and the practice being followed i ‘This stndard covers examination reconditioning and the criteria for declaring an used LPG cylinder unserviceable Manufacture, possession and use of any gas, when contained in cylinders of more than 500 mi water capacity in compressed or liquefied state, are regulated under the Gas Cylinder Rules, 2004, ofthe Government of Inia, This standard has been formulated in consultation and agreement with the statutory authorities under those rules. nit with the latest technological alvancement the country for the reconditioning of LPG eylindess. For the convenience, itis divided into followirg two sections: Section | Inspection ‘Section 2 Detaled examination ané reconditioning Inthe revision ofthis standard following major changes has been done 8) Title moslfed earie it was ‘code of practice’ now ‘requirement standard 'b) Clause 6 forexternal examination has been modified and more detils are provided regarding the rejection criteria in the tabulated form, (©) New Clause 4 ‘General’ has heen added, 4d) Clause for dedenting is removed, that is dedonting not permitted, ) Clause 12 Heat treatment modified ‘The composition of the Committee responsible for the formulation of this standard is given in Annex B. For thepurpose of deciding whether a paricular requirement f this stndar the final value. observe or calculate, ‘expressing the resul ofa test or analysis, shall be rounded of in accordance with S 2 : 1960 ‘Rules for rounding off numerical values (revised)’. The number of significant places retained inthe rounded off value should be the same 2 that of the specified value in this standard,15 13258: 2014 Indian Standard WELDED LOW CARBON STEEL CYLINDERS EXCEEDING 5 LITRE WATER CAPACITY FOR LOW, PRESSURE LIQUEFIABLE GAS — REQUIREMENTS FOR INSPECTION AND RECONDITIONING OF USED LPG CYLINDERS ( First Revision ) 1 SCOPE This standaed lays down the requirements for the inspection, materials, procedure, testing and marking for reconditioning of wsed LPG cylinders manufactured 1s per 1S 3196 (Part 1) : 2006 “Welded low carbon steel cylinders exceeding 5 lite water capacity for low pressure Tiquefiable gases : Part 1 Cylinders for Iiguetied petrokum gases (LPG) — Specification (th revision of capacity exceeding 5 litre und up t and intuding 250 te. This standard is nt applicable for periodic inspection and testing of LPG cylinders 2 REFERENCES {he standards listed in Annex A contain provisions, Which through reference in this text, constitute provisions to this standard, At the ime of publication, te editions indicaled were valld, Al! standards are subject Wo revision and partes to agreements based on this standard are encouraged to investigate the possibility of applying the most recent editions ofthe Standard indicated in Annes A. 3 TERMINOLOGY For the purpose ofthis standard, the definitions given, in IS 7281 : 1981 “Glossary of terms used in gas cylinder technology’ and the following sball apply. 4M Competent Person —A person appointed by the testing agency and who by a combination of training, ‘perience and supervision is able to make objective judgments on a subject, 32 Gross Weight — The sum of the tare weight of cylinder and the maximum weight of the LPG permitted init 33, Manufacturer — Means approved LPG cylinder Inanufacturer under ga cylinder rules. 3 Owner — The owner means the oil company who ‘owns LPG eylinder 35 Pit —A local comosion not in excess of 6 mm diameter and occurring not more frequently than one {in any 500 mm? ofthe surface. 3.6 Rejection — Putting cylinder out of service until finally deshaped 3.7 Repairer — Any agency having facilities and ‘capabilities to cay out he reconditioning of sed LPG cylinder as per the standard, SECTION 1 INSPECTION 4 GENERAL ‘The details of Inspection and reconditioning, shall be submited by the repairer to the inspecting authority forfinal approval by statutory authority. 5 INSPECTION EQUIPMENT AND METHOD OF MEASUREMENT Exterior corrosion, devting, bulging, gouges or dips arenormally measured by simple direct measurement with scales or depth gouges. The defect can also be measured using arigid straightedge of sufficient length placed over the defect and a sale is used to measure {he distance from the bottom of the straight edge to the bottom of the defect. Suitable depth gauges may also be used for measuring the depth of small cuts of pits, When measuring cuts, the upset metal shall be removed or compensated For 2 that only actual depts ‘of metal removed from the cylinder wall is measured. 6 EXTERNAL EXAMINATION 6.1 External Inspection ‘The entire surface shall be inspected by a competent person for, 1) dents, cus, ouges. bulges racks, laminations ‘orpunctures, botiom shel thickness, foot ring bottom clearance applying the criteria for rejection given in Table 115 13258: 2014 ‘Table 1 Physical Defects inthe Cylinder Wall [Clause 5.1(a] ‘SiMe, Dec Dectipon Rejection Cea We eh a ry > bage ‘Vil wang of ie eyader Rejetea allows a) Dest Depression inthe line tat has either petertednor a) Dethof det i reer than Uh the ‘enone he meal ‘ets daca of tb) Meat dame the den ater han oe quater of the dao of endo ©) Beto ace wed WW) Cotorgoog: Stu impeasion here met has en mee or 7S mmr mein eng wbe he deh feat east instch bt the ndemaed (ean) wll thickness esha te muna se ‘helen 15) Imesectingcut Pont ofiaenectio of wo more cus or sce ejection ial eiee ope Renee Deu deri wihin whence Whee fd ot pug cae Seeronige gros Simension frre fal dle v) Ca Asli or tin theylndr sb Rejection in all eases vi) Lamination Layering ofthe muti witin the clndr wall ppeing Rejection in lene ‘st tdiscontnary, cack. Lap or bulge a he rtace i Die ‘A sap deresson where th srface material hasbeen 7S mm ot morn enghand 4m om in pia san {8) Botom shell "Thies ete botom of te cline suine ‘Les tha nia alte wal ih then 1) Footing ——_Cleranc fhe body bot rom he grant 1) Leshan 8am forylinden af watercpaiy ‘com ups ire lewce by sina 1 mm forcings water ‘apatyexceting ean yp 9 ie «Leshan 25mm foeslindes of wae ‘Spay eaceang SO Cynder shal erected incase the oberved ike ofthe same srmsining wal in he fect portn en an the nur allt wall bike ‘Table 2 Corrosion Defects in the Cylinder Wall [Clause 6.1(b)) ons a iy Detects a ‘eserptbn Rijection Criteria m wold erosion pit Ping of metal cccring in Walaed ates at a Depth of pnetratin of any pc eceds OF Aes coreson Sari ares, Redon in wall ticknes over an ate it temang 3) percent of he yl race Inca he ends ad atom) Geel cersion Reduction wal hicknse over an een Linecomooe ‘soeding percent ofthe ender sarice Sets of pit corde cats of tied with sling tbe lenge around coneion rcemterence Cenvicecotion —Cenvice carasion_ seus the sea of the Inenection othe foting say pate wh the int Depth of pencnatoa of a pi ees 4 mm ejection inal he canes 1) Toa gh (coro am dein ing 1) Depth peneration ase 04 ©) Depth nen camo be nesta ‘When the dept of pencrason excess 0.4 wh the det of son cunt hs man1913258: 2014 Table 3 Other Defects [Cause 6.10)] Se Bee Deeirion aeson Criteria a ‘a or o 0) Dopssedbang Dave ichong which akan he pile oe ner ‘jon all ces |i) Acortashbuns ‘ring o thecylindr base el ‘hardened teat fete Zoe, te aton of Rejection inal case ‘strani wed metal or removal f metal by apg erate Ai) ne damage Een genial oe eatin et 5) Chngg we baring a pau 8) Fee daa ofthe metal 8) Darton ther ‘Metin ot meu vase pn 2) Metin fstey ea gf the cylinder vl inated by Rejetoninallexses tn cat of superiialcaring of pint eli muy be aceped b) corrosion, giving special attention to areas “where water can be (rapped, atthe base of the cylinder, the junction between the body and 3 Footting, the junction between the body xd valve guard or shroud, applying the ciiteria for tejetion given in Table 2 cotter defects (for example, depressed bung co fire damage), applying the criteria for ‘ejection given in Table 3. 8 Any cylinder rejected by the competent pesson shall ‘he segregated in accordance with 1 ‘SECTION 2 DETAILED EXAMINATION ‘AND RECONDITIONING 7 DE-GASSING OF CYLINDERS 7.1 Cylinder shall be degassed by sultable method and such cylinder shall be chocked to ensure complete ‘dogassing. The de-gassing station and procedures stall have the approval ofthe statutory aulbrity. 7.2 Valves of eylinders taken for processing shall be removed by employing «proper fixture anda suitable wrench using aclse fiting hexagonal adopter. It shall he ensured that only depressuriced cylinders are taken for the removal of the valve. 8 MATERIAL "hemateral used for manufacturing the replacements ‘of dotachables like shroud, valve protection ring snd ‘ootring shall be as specified in 1S 3196 (Part 1). The lube used for making valve protestion ring. sball conform tothe owner's requirement as detailed in their drawing. © REPLACEMENT DETACHABLES. 9.1 ‘The design of all detachables shall meet the requirements laid down In 18 3196 (Part 1) for inividual parts espectively and shall be inline with the approved drawing of owner 91. ‘The design shall conform to the owner's requlsement as detailed in their drawing, 9.1.2 The straightness and verticality of finished cylinders shall be as per IS 3196 (Part). 9.1.3 The eccentricity ofthe welded VP ring shall be as perIS 3196 (Par 1), 9.1.4 The fot ring shall he fitted a per 3196 Part 1) 10 DETAILED EXAMINATION 10.1. Cylinders received for reconditioning shall be ‘examined in accordance with Sesion | 10.2 External Cleaning Bach cylinder shall be cleaned extemally by wite brushing, water jet abrasive cleaning, approved chemical cleaning or any other suitable method, 103 Internal Cleaning Each cylinder shallbe internally cleaned by any ofthe following methods 10.3.1 Where the interior of the cylinder is contaminated by oil or otber similar Duid it shall be cleaned by one of te following methods: a) Steam cleaning: 'b) Washing out with an approved solvent; and ©) Use of magnet to remove metallic pars 10.3.2 Where the interior of a cylinder is affected by ‘ust or other foreign matter it shall be cleaned by one of the following methods: 4) Approved blasting, rotary wire brushing rumbling procedare; or 1b) Bumt out reatment in a furnace not exceeding temperature of the cylinder to more than 300°C for a period not exceeding I h since ‘ovetheating could change the mechanical ‘properties ofthe cylinder. After this all free ‘ust and scale shall be removed by methods as given in 103.115 13288: 2014 10.4 Tare Weight Yeritleation ‘After degassing and through cleaning (internally and externally), eylindets shall be checked for correct determination of the tare weight (weight of the empty cylinder with valve and its safety cap, footring and V.P ring). Any eylinder having lost its tare weight by over 5 pereent ofits original tare weight shall be declared unserviceable, 10.5 External Inspection 105.1 Affected postions ofthe body ofthe cylinders Segregated during inspection under Section 1 saall be round to achieve adefect fre surface. 10.8.1. Cylinder wall thickness so achieved shall not bo less than minimum ealeulated wall thickness as per [8 3195 (Part). 106 Internal Inspection ‘The entice internal surface of the cylinder shall be examined by means ofan extra low voltage inspection lamp andthe eylinder shall be declared unserviceable, ifthe bottom of an internal defect cannet be seen and its extent cannot be measured. 11 SEGREGATION OF CYLINDERS Cylinders on the bass of inspection shale segregated in accordance with 11.1 and 11.2 1A Unserviceable Cylinders with any one oF more of the following conditions shall be declared unserviceable: 4) Cylinders declared unserviceable when inspected according to Section 1 ) Cylinders having lost. their identity (Macufacturer's mame, serial number of the cylinder, test date and original tare weight); ©) Cylinders coming for repairs forthe second time; and, 44) The eylinders having wall thickness fess than the minimum thickness as permitted in 1058. Cause(s) of rejection of all the unserviceable cylinders shall be recorded in the performa ss shown in Annex B and cause may be coded inthe following manner: Bulge Bt Burn E Dent Bs Dig 2 Et cu ES Pit ES Line corrosion fer General corrosion Bung thread damage Loss in tare weight Idetity lost, Ell Cylinder identified as once repaired; E-12 ‘The ottom of inernal defect cannot: 1-1 ‘be seen and i's extent cannot bbe measured ‘The wall thickness has been reduced : 1-2 by more than the specified value 112 Repairable Cylinders which are found serviceable according 0 10.1 and 11.1 shall be considerec repairable, These cylinders shall be taken for further processing and reconditioning. When repaired, both the footing as ‘well asthe V Pring shall be replaced. 12 RE-CONDITIONING 121 Removal o Footring and Valve Protecting Ring, 121.1 Foot ring and valve protecting ring shall he removed without damaging the body of the cylinder ‘The welded spots shall be ground and cleaned thoroughly for checking the surface for line eoroion tse, and wall thickness efor iting ew toons nd valve protesting ong 122 Fixing New Footring and Valve Protecting, Ring/Shroud New footing and valve prowecting ring/shroud shall he welded in accordance with I$ 3196 (Part 1) and all ‘welds shall be inspected for weld defects. 13 HEAT TREATMENT 13 Cylinders shall be efficiently and uniformly ress relieved as approved by the statutory authority after completion of welding of attachments and before hydrostatic testis applied. A complete record 0! the ‘heat treatment cycle shall be maintsined. 132 Localized heat treatment shall not be permits. NOTE — The sess sanulcuring of the process 14 HYDROSTATIC TEST 141 Each heat treated cylinder shall he subjected to hydrostatic test. Dusing the hydrostatic test, the pressure shall be increased gradually til the required test pressure is reached. Alter the test pressure is reached and the external surfaces of the cylinder are died, it shall be retained for a peried of not less than 30s. Any reduction in pressure noticed during this retention period or any leakage or visible bulge ot levine cycle sl be quali ay 9 inde raves feng woke hedetonation shall be treated as a case of failure i the test and the eylinder shall be declared unserviceable 14.1 ‘The value of hydrostatic test prossure for LPG shall be taken as 25 kgficm? as specified in IS 3196 (Part, 14.12 Hydrostaic test shall be caried out as per IS 9190 (Pan 3) 15 FIXING OF VALVE 1 Valve Connection Prior to fiving the valve, the bung threads shall be ‘leaned using @ machine ap of the same thread profile asthe bung threads, The cleaning shall ensure freedom from grit, ne and other forciga mater, if any. Alsoit shall ensure, breaking of scale formed on the thread and -correction of any distortion, experienced during hea reatment Valve suitable for intended use and conforming to IS. 8737 shall be fitted to the cylinder using approved jointing compound atthe torque of 200 + 20 Nm, after ‘ensuring that internal cleaning ofthe cylinder has been done for removal of any water, grit, welding lag, lux, ictal or any other foreign particles 16 PNEUMATIC TEST. 16.1 Each cylinder after it has been dried and fited With valve shall be tested for leakage by subjecting to wessure of not Tess than 12 kgllem?® a period of n while immersed in water and shall show 20 kage from the body of the cylinder and the joint hocwoen valve and bung. This test shll be cated et ste fining the safety cap onthe valve 16.2 Pncumatic leakage test shll be carried out as per 1S 3196 (Part 3), [NOTE — Suiablesr dying meds may be adopted a ge shy ee condense pose! heeds Cylinders declared unserviceable during inspection! tests shall be de-shaped as per Gas Cylinder Rules, 2008 18 PREPARATION FOR DESPATCH, 18.1 All cylinders shall be thoroughly cleaned and dried internally before being fined with valves. 18.2 The outside surface shall be grit (see 1S 4683) blsted withiminimam SA2.5 grade of bast (xe 1S 9954) and shall be given following protective coatings: 2) Spraying zine to give a coating of minimum thickness of 37 unless otherwise agreed 10 bbaween the purchaser and the manufacture, 41813258: 2014 ‘The zine wire used for spraying shall be as per IS 12447 and the zine spraying shall be as per IS 6586. bb) Onecoat of ine chromate primer as agreed to ‘between the purchaser and the manufacture, ©) One coat of synthetic enamel paint ‘conforming to 1S 2932 of signal red colour (Shade No. 537 of IS 5) or any other colour withthe approval of statutory authority 4d) Asanalterate to (a), (b) and e) eylinders shall bbe powder coated (see IS 13871) or stoving primer coated (see I$ 2078) and enamel coated (see 18 2932) as per the agreement between the epairerand the owner, ‘The total mirimum combined coating thickness shall be 674, [NOTE — Pncedue for mesure of oan of thickets: 8) Five ange readings for ach spt shall be taken moving (Ge professor dance or echew gauge ada with igh low gauge realing tat cant be repeated consi Tae the werae of the five gage readings SS spot measurement 1) Make fe such pot mesuremcus appesnatelyevely spaced oer the srface ofthe evinder ach pt measurement sl at te below 80 pte of be specifi minimom thickest ané average ofthe fe #9 19 RECORDS A record shall be maintained for all tests, reconditioning and inspections athe cylinder repairer's works and copies shall be made available to the inspecting authority and owner of the cylinder, if desired, A test certificate duly approvedand signed by the inspecting authority shall te forwarded to the statutory authority and the owner (see Annex C)- 20 MARKINGS 20.1 The cylinders fitted with new footring and V. P. Fing shall be imumediately marked with the following ‘markings on the footring and vertical stays of VP ring as applicable: 8) Original serial number and batch namber of the eylinder: b) Original BIS certification mark and ‘manufacturer's name orits initials; ©) Repairer’ identification initials/monogram:; 4) New tare weight and gross weight of cylinder, in kg: ©) Month and year of manufacture, retest and reconditioning: f) The maximum working pressure, test pressure, in MPa: 2), Water capacity in litres;1813258: 2014 ANNEX B (Clause 11.1) LIST OF CYLINDERS UNSERVICEABLE, ‘Repuirer’s name Order No. Batch No, Certificate No, Date ‘Original Manufacurer's Date of Date of Cause Name Manufucture Rejection of Rejection ing company’s Inspecting officer representative ANNEX C (Clause 19) LIST OF CYLINDERS ACCEPTED Repairee’s name Onder No, Batch No, Cerificate No. Date Gllinder Original Manufacturer's Date of Date of Details SiN, Name Manufacture Repair/Test of Repairs : Carried Out Repairing company’s Inspecting officer representative