Periodic Inspection Report For Lpg Cylinders

BUREAU OF INDIAN STANDARDS REPORT OF PERIODIC INSPECTION FOR LPG CYLINDERS ( ………………. Inspection since the Grant of Licence / Renewal ) CM/L-

IR No. ……………………………

Valid upto :

Date of writing IR ………………

1.

a)

Licensee : IS 3196(Part 1):2006 Product: Welded low carbon steel cylinders for liquefiable petroleum gas (LPG) excluding 5 litres WC. Size/Grade/Variety :

b)

Other licences held :

CM/L-No

2

Special inspection charges, if applicable

3

Date of inspection

4

Person(s) contacted

5

a)

Date

c)

Conclusions and recommendations

d)

Despatch details of last two Samples

IS

Product

b) Conducted by

Sl No. Date of drawal of sample 1.

Date of despatch of Samples

Test result : Pass/Fail, if available

2. 6

Action on advice rendered in previous inspection or otherwise asked for while granting licence/renewal of the licence

REMARKS OF THE REVIEWING OFFICER ( ON IRs,TRs, General, etc.) 1. 2. 3. 4. 5. Reviewing Officer’s Name and Designation: Date of Review

:

7.

Changes since Previous Inspection a)

Technical

b)

Administrative

8.

Description of Article(s) being manufactured at the time of inspection , stagewise

9

Raw materials a) Name of major ones

Supplied by

i) LPG Steel ii) Bungs b)

Maximum and minimum values of principal requirements from Test Certificates Sl No.

c) 10.

11

Requirements

Variation in test values

1. 2. 3. 4. 5. Disposal of sub-standard raw materials

Production and supply since last inspection (details of completed month to be furnished) Month

a)

Quantity produced

b)

Quantity marked

c)

Quantity unmarked and manner of disposal

d)

Reasons for not marking

e)

Parties supplied to ( Give complete address)

Storing , Packing and Marking of BIS material a) Material held in stock b)

Condition of storing

c)

Packing and marking on packages

d)

At what stage marking is done (after or before test results are known )

e)

Any change in the marking procedure from approved one

Quantity

12.

13.

14.

Production Control (As observed from test and other relevant materials) a)

How is the control system being operated

Satisfactorily/Not satisfactorily

b)

Variation in test result for principal requirements ( append test results, if necessary, or if required by the Instruction sheet for the Standard)

Sl. Requirement Variation in test values

c)

Are the test records maintained satisfactorily vis-à-vis STI for the product

d)

What is the percentage of rejection – stagewise, their reasons and manner of disposal ? (Indicate batches disposed)

e)

Whether the failure is due to inherent cause(s) or chance cause(s)

Testing in factory a)

Please see Annex I

b)

Are the instruments used calibrated periodically ? Please see Annexure II

c)

Are the instruments used reasonably accurate ?

d)

Any addition to the existing testing equipment

e)

Any comments on testing, testing equipment, testing personnel, etc.

Samples for Independent Tests a)

Sl.No.

Description

Batch/C.U. No.

b)

From where sampled (Stock or production line)

c)

Test record of the batch from which sample is drawn Sl. No. Requirement

d)

Give details of packing, labeling, coding, etc. of the sample

e)

How sealed ? Give impression of seal used

Date of Manufacturing

Recorded test values

15.

f)

Samples brought in or left with the firm despatch to BIS or outside testing laboratory ?

g)

Details of counter sample left with the firm and the manner of packing, labeling, coding, sealing etc. and also give impression of the seal

h)

Any further information

Conclusions and Recommendations a)

Has the scheme operated satisfactorily for the period since last inspection ?

b)

If operated unsatisfactorily, give reasons

c)

Assessment of the operation of the scheme based on the present vis-à-vis past performance

d)

Any discussion with the firm on any point of interest, such as manufacturing difficulties, in-process control, testing procedure or any difficulty/irregularities observed in the operation.

e)

Any action to be taken including suspension

f)

Any other observation/comments for better appraisal of the report

Satisfactory / Not satisfactory

Signature

:

Inspected by (Name)

:

Designation

:

Date

:

No. of Enclosures :

Station

:

ANNEX – I Details of Checks/Testings in Factory 1. BUNGS Select 5 bungs from already inspected lot and check the following : i) Visual Inspection

Satisfactory / Not Satisfactory

ii) Dimensions

iii) Threads with L1 , L9 , C1 & C2 gauges

Satisfactory / Not Satisfactory

iv) Markings a) Whether markings are as per approved drawing

Yes/No

b) Markings are legible

Yes/No

v) Check test records 2.

CIRCLES i) Whether gauges used for dimensional check Dimensional Check

Yes/No Satisfactory / Not Satisfactory

ii) Visual defects on 5 circles iii) Check test records 3.

DEEP DRAWING & TRIMMING i) Check 5 halves for die/scratch marks/wrinkles/cracks etc.

Satisfactory / Not Satisfactory

ii) Check for edge preparation

Satisfactory / Not Satisfactory

Iii) Check for records 4.

BUNG HOLE PUNCHING Check deformation and concentricity of bung holes on 5 halves

5.

Satisfactory / Not Satisfactory

DEGREASING i) Check whether hot water with caustic soda is being used

Yes/No

ii) Temperature of bath iii) Whether degreasing is proper 6.

Yes/No

HALVES DIMENSION i) Whether goose neck dial gauge being used for thickness checking is in working condition

Yes/No

ii)Check availability of ultrasonic thickness gauge and whether gauge is in working condition

Satisfactory / Not Satisfactory

7.

8.

9.

BUNG WELDING i) Whether hand welding or submerged arc welding

Hand/ submerged arc welding

ii) Whether flux is preheated/sieved before use in submerged arc welding

Yes/No

iii) Quality of weld and cleaning ( check 5 pieces )

Satisfactory / Not Satisfactory

BACKING STRIP WELDING / JOGGLE JOINT i) Whether fitment of backing strip is proper

Yes/No/NA

ii) Check whether joggle joint is proper

Yes/No/NA

CIRCUMFERENTIAL WELDING i) Whether the flux is preheated/sieved before use

Yes/No

ii) Check quality of weld on 5 cylinders

Satisfactory / Not Satisfactory

iii) Check welding parameters Electrode size (mm) Welding Current(Amps)

10.

11.

Voltage (Volts)

Speed ( Sec/Rev)

FOOT RING WELDING i) Whether welding is equispaced and minimum 40 mm length is being maintained

Yes/No

ii) Whether foot ring joint is below one of the weld

Yes/No

iii) Welding quality of foot ring & cleaning ( Check 5 pieces )

Satisfactory / Not Satisfactory

V P RING ASSEMBLY AND WELDING ON CYLINDER BODY i) Whether V P Ring joint is positioned on one of the stay plates

Yes/No

ii) Whether stay plates are welded vertically at equidistance

Yes/No

iii) Whether welding has been done on both sides of stay plates

Yes/No

iv) Quality of weld & cleaning

Satisfactory / Not Satisfactory

v) Whether punching on stay plates & their sequence is as per drawing

Yes/No

vi) Whether punching is legible

Yes/No

vii) Check bending of stay plates due to punching

Satisfactory / Not Satisfactory

viii) Use of fixture for V P ring assembly to ensure concentricity 12.

HEIGHT i) Check use of proper gauge for height measurement

Satisfactory / Not Satisfactory

ii) Check 5 cylinders for proper height

Satisfactory / Not Satisfactory

13.

14.

HEAT TREATMENT i) Type of furnace

Batch Type / Continuous Type Oil Fired / Electric

ii) Whether timer is provided

Yes/No

iii) Check temperature controller, temperature recorder graph etc are in working condition

Satisfactory / Not Satisfactory

iv) Check the graphs for date, time, batch no. and ensure stress relieving temperature and soaking time is maintained

Satisfactory / Not Satisfactory

HYDROSTATIC TEST i) Whether HST arrangement is adequate to cope with production

Yes/No

ii) Test 5 cylinders for HST

Satisfactory / Not Satisfactory

iii) Check HST records iv) Is lighting arrangement adequate 15.

16.

Yes/No

SHOT BLASTING i) Check shot blasting on body, V P Ring assembly, inside of foot ring, etc.

Satisfactory / Not Satisfactory

ii) Protection of bung threads during shot blasting

Satisfactory / Not Satisfactory

METALLIZING, PRIMER AND ENAMEL COATING i) Quality of metallizing

Satisfactory / Not Satisfactory

ii) Uniformity

Satisfactory / Not Satisfactory

iii) Thickness Metallizing

With Primer

With Enamel Paint

Cylinder Body VP Ring Assembly Foot Ring 17.

18.

INTERNAL CLEANING & BUNG TAPPING i) Whether internal cleaning being done by magnet, light with vacuum

Yes/No

ii) Whether hot air/compressed air used to remove water traces

Yes/No

iii) Check cylinder bung threads with L1,L9,C1,C2 gauges on 5 cylinders

Satisfactory / Not Satisfactory

VALVE TIGHTNESS i) Whether proper torque wrench available

Yes/No

ii) Check torque on 5 already valve fitted cylinders

Satisfactory / Not Satisfactory

19.

20.

PNEUMATIC TEST i) Check 5 cylinders for pneumatic test

Satisfactory / Not Satisfactory

ii) Whether water tank inside walls painted white and illumination is proper

Yes/No

iii) Whether water is clean

Yes/No

iv) Check test records

Satisfactory / Not Satisfactory

TARE WEIGHT i) Whether balance is proper & in working condition

Yes/No

ii) Range of balance iii) Least count of balance

21.

22.

23.

iv) Select 5 cylinders from already tare weight punched batch & check tare weight

Satisfactory / Not Satisfactory

v) Check records

Satisfactory / Not Satisfactory

ACCEPTANCE TESTS / BURST TESTS i) Witness acceptance and burst test, if carried on during the day

Satisfactory / Not Satisfactory

ii) Whether tensile testing, bursting test equipment is in working condition

Yes/No

iii) Check records

Satisfactory / Not Satisfactory

HYDROSTATIC STRETCH TEST (HSST) AND WATER CAPACITY TEST i) Check arrangement for HSST and water capacity test

Satisfactory / Not Satisfactory

ii) Check 2 cylinders for these requirements if stress relieved cylinders are available before HST

Satisfactory / Not Satisfactory

iii) Check records

Satisfactory / Not Satisfactory

REJECTION i) Check rejection records ii) Check deshaping records

24.

25.

BIS TEST CERTIFICATION Check for certificates for cylinders already despatched & co-relate with test records STORAGE OF RELEASED CYLINDERS i) Whether cylinders are properly stored, safety caps fitted on valves

Yes/No

ii) Check complete air evacuated from cylinders

Satisfactory / Not Satisfactory

Annex II CALIBRATION RECORD Name of instrument/gauge 1. Tensile testing machine 2. Temperature recorder 3. Pyrometer 4. Pressure gauges i) ii) iii) iv)

5. Thread gauges i) L1 ii) L9 iii) C1 iv) C2 6. Ultrasonic thickness gauge 7. Weighing machine 8. Gauges used for dimensional checks

Date of calibration

Remarks