High pressure cylinders
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The document discusses various topics related to steel production, including images sourced from Flickr and Google of steel mills and cylinders. It also references websites about steel companies, specialty gases, and safety management. Throughout, it provides attribution for different sources by listing URLs and dates.
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High pressure cylinders
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- 4. 2/29/2016 4Image sources: Google images
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- 15. 2/29/2016 15 Source: http://www.alspecialtygases.com/ Source: http://hazard.com/graphics/Safety_Managment
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Editor's Notes
- High Pressure Cylinders are vessels used to store fluids (gases or liquids) at a pressure substantially higher than ambient pressure. They are equipped with hemispherical or torispherical end caps called heads. Various fatal accidents have occurred in the history of manufacturing of high pressure cylinders; hence they are generally regulated by engineering authorities backed by legislation.
- High pressure cylinders were first manufactured in Great Britain during the era of industrial revolution. They were used as boilers to drive steam engines. During the initial times, many fatal explosions occurred and as a consequence, design standards were implemented. Various testing and certification procedures were developed to ensure the safety of the concerned people.
- Automotives: Natural gas is considered one of the most attractive alternative fuels. CNG steel cylinders are widely used in the automotive industry. Boilers: High pressure vessels are also used as boilers in power plants. Industrial Gases: They are used for storing high pressure oxygen, hydrogen, nitrogen or liquefied gases used at the industries. Firefighting: Its application can be extended to high pressure CO2 cylinders used in fire extinguishers. Beverage: High pressure CO2 cylinders are used to dispense carbonated soft drinks and other beverages. Cooking: High pressure cylinders are used to store LPG used in kitchens for cooking purposes.
- Any material with good tensile properties and is chemically stable in the chosen application could be employed. Generally, these cylinders are made up of steel and it is rolled and welded to form cylinders. Carbon fiber is also sometimes preferred due to its high tensile strength but they are difficult to manufacture. These days, seamless tubes are also being chosen as starting cylinders.
- Now I will stepwise discuss the manufacturing process of this high pressure cylinders.
- Raw Material: Raw Material is in form of seamless cylinders of various sizes and thickness. Then they are cut into desired length depending upon the storage capacity. Induction Heating: Both the ends of the cut cylinder are inserted in an induction furnace one by one before spinning the respective end. Bottom and Neck Spinning: After the respective end is heated, each end is spun according to the required shape and geometry. Neck Opening: Then is the process of neck opening. In middle of the neck spun part, a hole is grilled as an opening to allow gases go through it.
- Hardening: The product obtained is now passed through a hardening furnace to harden and increase the mechanical strength of the material. Quenching: Now rapid cooling of the workpiece takes place to reduced Crystallinity in order to increase toughness of the work part. Tempering: This process of heat treatment is used to toughen the cylinder formed in the previous step. The hardness of the cylinder is reduced by heating it to a temperature lower than that used during the hardening process. This is a more controlled heating process in which the exact amount of hardness required is achieved. Neck Machining: Now the hole grilled during the neck opening process is machined to be cut into desired length and form threads on the inner or the outer surface using CNC machine as per the requirements.
- Grit Blasting: In this process, abrasive particles hit the surface of the cylinder for cleaning purposes and surface treatments for modifying the surface properties as required. Mass Check: The cylinder obtained after grit blasting process is now weighed to ensure that theoretical mass of the cylinder matches the one just manufactured. Water weight capacity is also checked during this process.
- As mentioned earlier, manufacturing of high pressure cylinders is hazardous and various safety precautions should be kept in mind while they are used. To ensure upmost safety and avoid any accidental damage, various checks are performed on each cylinder manufactured. Few of them which are practiced across the industries are
- Ultrasonic Inspection: In this check, ultrasonic pulse-waves are transmitted into the cylinders to detect internal flaws and measure the thickness of the cylinder wall. Mechanical Test: Cylinders are dropped from height to measure the impact force they can sustain. Also, bullets are fired on the product to ensure good quality of the product. Hydrostatic Stretch Test: This test is carried out to check cylinder strength or to identify any fluid leakage. Generally, a fluid with almost twice the working pressure is filled in and dyed for visual identification of any leakage. Pressure measurements are also carried out to keep a check on leakage.
- Cyclic Pressure Test: Performed for durability tests of the cylinders. In this process, the cylinders are exposed to rapid pressure changes. Pressure waves are automated from the machines and the check is performed on cylinders for its applications in heat exchangers and power trains. Internal Cleaning: Now the internal and external surfaces of the cylinder are cleaned using respective shot blasting machines. Painting and Final Inspection: Now the cylinder is painted and mass checks are carried out.
- Bonfire Test: Cylinders thus obtained are roasted over roaring bonfires to ensure the safety of cylinders over high temperature. Final Threading: Before shipping the cylinders to the customers, manufacturers generally carry out the final threading process and attach valves if required. Air Leakage test: and after threading it is mandatory to test the air leakage, which ensures that no gases will be leak.
- After all the safety checks it’s time to pack the cylinders and send it to the customers.
- Color Coding: High pressure gas cylinders are usually color coded but the pattern is not followed everywhere. Hence, color of the cylinder cannot be relied upon for the product identification and one should refer to the labels attached with them. Design: Different design standards are followed in different countries. ASME Boiler and Pressure Vessel Code in North America, the Pressure Equipment Directive of the Europe are couple of standards which prescribe the working pressure and temperature of the cylinder.
- Leak before burst: High pressure cylinders with this feature are designed in such a way that any crack that happens to be present in the wall grows throughout allowing the fluid to escape the cylinder to be diffused with the environment. This feature allows us to avoid any fracture or blast during operation. Safety Valves: High pressure cylinders are generally equipped with safety valves which helps in reducing pressure in return allowing the product to operate at optimum pressure.
- THIS IS THE TYPICAL ENGINEERING DRAWING OF THE TYPICAL CYLINDER.
- Since cylinder technologies are having a vast area to discuss about but due to the minimum allowing time, That would be all from my side.