Beruflich Dokumente
Kultur Dokumente
By
Kedar Rajendra Gosavi
A PROJECT REPORT
Submitted to
BHARATI VIDYAPEETH UNIVERSITY
Bonafide Certificate
Certified that this project report titled Market Analysis for Export of CNG Pressure
Cylinders to Uzbekistan is the bonafide work of Mr. Kedar Rajendra Gosavi who carried
out the research under my supervision. Certified further, that to the best of my knowledge
the work reported herein does not form part of any other project report or dissertation on
the basis of which a degree or award was conferred on an earlier occasion on this or any
other candidate.
Abstract
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Acknowledgement
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Table of Contents
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List of Tables
Page |7
List of Figures
Page |8
Chapter 1
Introduction
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Pressure Vessels
A pressure vessel is a closed container designed to hold gases or liquids at
a pressure substantially different from the ambient pressure.
The design, manufacture, and operation are regulated by engineering authorities
backed up by laws. For these reasons, the definition of a pressure vessel varies from
country to country, but involves parameters such as maximum safe operating pressure
and temperature.
Pressure vessels are used in a variety of applications in both industry and the
private sector. They appear in these sectors as industrial compressed air receivers and
domestic hot water storage tanks.
No matter what shape it takes, the minimum mass of a pressure vessel scales with
the pressure and volume it contains and is inversely proportional to the strength to
weight ratio of the construction material (minimum mass decreases as strength increases)
Design Requirements
Test pressure
The minimum test pressure used in manufacture shall be 300 bar (1.5 times working
pressure).
Burst pressure
The minimum actual burst pressure shall be not less than 450 bar.
Stress analysis
The stresses in the cylinder shall be calculated for 200 bar, test pressure and design burst
pressure. The calculations shall use suitable analysis to establish stress distributions to
justify the minimum design wall thicknesses.
Maximum defect size
The maximum defect size at any location in the metal cylinder such that the cylinder shall
meet pressure cycling and LBB requirements shall be specified.
Openings
Openings are permitted in heads only. The centre line of openings shall coincide with the
longitudinal axis of the cylinder.
Fire protection
The cylinder design shall be protected with pressure relief devices. The cylinder, its
materials, pressure relief devices (PRD) and any added insulation or protective material
shall be designed collectively to ensure adequate safety during fire conditions. Pressure
relief devices shall be approved to a standard acceptable to the Inspector in the country
of use.
Attachments
When a neck ring, foot ring or an attachment for support is provided, it shall be of
material compatible with that of the cylinder and shall be securely attached by a method
other than welding, brazing or soldering.
Any coatings applied to cylinders shall be such that the application process does not
adversely affect the mechanical properties of the cylinder. The coating shall be designed
to facilitate subsequent in-service inspection.
Materials
Steel
Steels shall be aluminium- and/or silicon-killed and produced to predominantly fine grain
practice.
Aluminium
Aluminium alloys may be used to produce cylinders provided they meet all requirements
of the International Standard and have maximum lead and bismuth contents not
exceeding 0,003 %.
Composite Materials
Resins
The material for impregnation may be thermosetting or thermoplastic resins.
Examples of suitable matrix materials are epoxy, modified epoxy, polyester and vinylester
thermosetting plastics, and polyethylene and polyamide thermoplastic material.
Fibres
Structural reinforcing filament material types shall be glass fibre, aramid fibre or carbon
fibre. If carbon fibre reinforcement is used the design shall incorporate means to prevent
galvanic corrosion of the metallic components of the cylinder.
Design Requirements
Test pressure
The minimum test pressure used in manufacture shall be 300 bar (1.5 times working
pressure).
Burst pressures and fibre stress ratios
The metal liner shall have a minimum actual burst pressure of 260 bar.
The composite over-wrap shall be designed for high reliability under sustained loading
and cyclic loading. This reliability shall be achieved by meeting or exceeding the
composite reinforcement stress ratio values.
Stress ratio is defined as the stress in the fibre at the specified minimum burst pressure
divided by the stress in the fibre at working pressure.
The burst ratio is defined as the actual burst pressure of the cylinder divided by the
working pressure.
The stress ratio calculations shall include
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Over-wrap
Fibre winding
The cylinders shall be manufactured by a fibre winding technique. During winding the
significant variables shall be monitored within specified tolerances and documented in a
winding record. These variables can include but are not limited to:
a) Fibre type including sizing;
b) Manner of impregnation;
c) Winding tension;
d) Winding speed;
e) Number of roving;
f) Band width;
g) Type of resin and composition;
h) Temperature of the resin;
i) Temperature of the liner;
j) Winding angle.
Curing of thermosetting resins
If a thermosetting resin is used, the resin shall be cured after filament winding. During the
curing, the curing cycle (i.e. the time-temperature history) shall be documented.
The maximum curing time and temperature for cylinders with aluminium alloy liners shall
be below the time and temperature which adversely affect metal properties.
Auto-frettage
Auto-frettage, if used, shall be carried out before the hydrostatic pressure test.
Exterior environmental protection
The exterior of cylinders shall meet the requirements of the acid environment test.
Exterior protection may be provided by using any of the following:
a) A surface finish giving adequate protection (e.g. metal sprayed on to aluminium,
anodizing); or
b) The use of a suitable fibre and matrix material (e.g. carbon fibre in resin); or
c) A protective coating (e.g. organic coating, paint);
d) A covering impervious to the chemicals.
Any coatings applied to cylinders shall be such that the application process does not
adversely affect the mechanical properties of the cylinder. The coating shall be designed
to facilitate subsequent in-service inspection.
Minimum actual burst values and stress ratios for Type - 2 cylinders
Materials
Steel
Steels shall be aluminium- and/or silicon-killed and produced to predominantly fine grain.
Aluminium
Aluminium alloys may be used to produce cylinders provided they meet all requirements
of the International Standard and have maximum lead and bismuth contents not
exceeding 0,003 %.
Composite Materials
Resins
The material for impregnation may be thermosetting or thermoplastic resins. Examples of
suitable matrix materials are epoxy, modified epoxy, polyester and vinylester
thermosetting plastics, and polyethylene and polyamide thermoplastic material.
Fibres
Structural reinforcing filament material types shall be glass fibre, aramid fibre or carbon
fibre. If carbon fibre reinforcement is used the design shall incorporate means to prevent
galvanic corrosion of metallic components of the cylinder.
Design Requirements
Test pressure
The minimum test pressure used in manufacture shall be 300 bar (1.5 times working
pressure).
Burst pressures and fibre stress ratios
The composite over-wrap shall be designed for high reliability under sustained loading
and cyclic loading. This reliability shall be achieved by meeting or exceeding the
composite reinforcement stress ratio values. Stress ratio is defined as the stress in the
fibre at the specified minimum burst pressure divided by the stress in the fibre at working
pressure.
The burst ratio is defined as the actual burst pressure of the cylinder divided by the
working pressure.
The stress ratio calculations shall include:
a) An analysis method with capability for non-linear materials (special purpose computer
program or finite element analysis program);
b) Correct modelling of the elastic-plastic stress-strain curve for a known liner material;
c) Correct modelling of the mechanical properties of the composite;
d) Calculations at autofrettage pressure, zero pressure after autofrettage, working
pressure and minimum burst pressure;
P a g e | 15
b) Manner of impregnation;
c) Winding tension;
d) Winding speed;
e) Number of roving;
f) Band width;
g) Type of resin and composition;
h) Temperature of the resin;
i) Temperature of the liner;
j) Winding angle.
Curing of thermosetting resins
If a thermosetting resin is used, the resin shall be cured after filament winding. During
curing, the curing cycle (i.e. the time-temperature history) shall be documented.
The maximum curing time and temperature for cylinders with aluminium alloy liners shall
be below the time and temperature which adversely affect metal properties.
Auto-frettage
Auto-frettage, if used, shall be carried out before the hydrostatic pressure test.
Exterior environmental protection
The exterior of cylinders shall meet the requirements of the acid environment test.
Exterior protection may be provided by using any of the following:
a) A surface finish giving adequate protection (e.g. metal sprayed on to aluminium,
anodizing); or
b) The use of a suitable fibre and matrix material (e.g. carbon fibre in resin); or
c) A protective coating (e.g. organic coating, paint);
d) A covering impervious to the chemicals.
Any coatings applied to cylinders shall be such that the application process does not
adversely affect the mechanical properties of the cylinder. The coating shall be designed
to facilitate subsequent in-service inspection.
Minimum actual burst values and stress ratios for Type - 3 cylinders
Fibres
Structural reinforcing filament material types shall be glass fibre, aramid fibre or carbon
fibre. If carbon fibre reinforcement is used the design shall incorporate a means of
preventing galvanic corrosion of metallic components of the cylinder.
Plastic liners
The polymeric material shall be compatible with the service conditions.
Metal end bosses
The metal end bosses connected to the non-metallic liner shall be of a material
compatible with the service conditions
Design Requirements
Test pressure
The minimum test pressure used in manufacture shall be 300 bar (1.5 times working
pressure).
Burst pressures and fibre stress ratios
The composite over-wrap shall be designed for high reliability under sustained loading
and cyclic loading. This reliability shall be achieved by meeting or exceeding the
composite reinforcement stress ratio values. Stress ratio is defined as the stress in the
fibre at the specified minimum burst pressure divided by the stress in the fibre at working
pressure.
The burst ratio is defined as the actual burst pressure of the cylinder divided by the
working pressure.
For type -4 designs, the stress ratio is equal to the burst ratio.
Verification of the stress ratios may also be performed using strain gauges.
Stress analysis
A stress analysis shall be performed to justify the minimum design wall thicknesses. It
shall include the determination of the stresses in liners and fibres of composite designs.
The stresses in the tangential and longitudinal direction of the cylinder in the composite
and in the liner shall be calculated. The pressures used for these calculations shall be 0
bar, 200 bar, test pressure and design burst pressure. The calculations shall use suitable
analysis techniques to establish stress distribution throughout the cylinder.
Openings
Openings are permitted in the end bosses only. The centre line of openings shall coincide
with the longitudinal axis of the cylinder.
Fire protection
The cylinder design shall be protected with pressure relief devices. The cylinder, its
materials, pressure relief devices and any added insulation or protective material shall be
designed collectively to ensure adequate safety during fire conditions
Pressure relief devices shall be approved to a standard acceptable to the Inspector in the
country of use.
Minimum actual burst values and stress ratios for Type - 4 cylinders
Chapter 2
Domestic Production & Consumption of CNG
Cylinders
P a g e | 20
- Aurangabad, Maharashtra
- Gandhidham, Gujarat
- Tarapur, Maharashtra
- Visakhapatnam, Andhra Pradesh
The parameters for the production of CNG Cylinders for domestic as well as for
the exports are laid down by the International Organisation for Standardisation (ISO) in
the article ISO-11439 titled as “Gas cylinders — High-pressure cylinders for the on-board
storage of natural gas as a fuel for automotive vehicles.” The first edition of this article
was published on 15ht of September 2000.
This article lays down the specific requirements for manufacturing of all the four
types of cylinders & the specific set of tests that all the cylinders have to go through in
order to be fitted in the vehicle.
Bonfire Testing
This test is performed in order to make sure that the gas will vent before the
cylinder is ruptured, when it is exposed to fire.
Apart from this test the gunfire testing, vibration of vehicle fuel system testing &
hydraulic crush testing is also performed in order to make the cylinder not to burst in any
condition possible.
Markings
On each cylinder the manufacturer has to provide clear permanent markings not
less than 6 mm high. Marking shall be made either by labels incorporated into resin
coatings, labels attached by adhesive, low stress stamps used on the thickened ends of
type CNG-1 and CNG-2 designs, or any combination of the above. Adhesive labels and
their application shall be in accordance with ISO 7225 or an equivalent standard
acceptable to the Inspector in the country of imports. Multiple labels are allowed and
should be located such that they are not obscured by mounting brackets.
Following is a flow chart of the process involved in manufacturing of the CNG cylinders
P a g e | 22
Growth in the cylinder industry is largely led by growth in demand for CNG
cylinders. Demand for cylinders has grown to a CAGR of 19% over FY06-FY09E.
Traditionally, high-pressure seamless cylinders catered to the medical, industrial, fire
fighting and beverages segment. The advent of CNG as an eco-friendly automotive fuel
has opened new avenues for the industry. At the same time, use of cylinders for other
purposes like medical, industrial and defence purposes is also growing at a steady pace.
The market for CNG and LPG cylinders, used for automotive purposes, is growing
at a fast clip. The need for a clean fuel and rising costs of petrol and diesel are leading to a
shift towards cleaner and less-expensive fuels. Taking a leaf out of Delhi’s experience,
other cities too are expected to shift to alternate fuels soon. The Supreme Court has
P a g e | 23
mandated that 28 cities should shift to CNG. This could open up newer markets and lead
to higher growth rates compared to other user segments. The CNG automotive cylinder
segment is the fastest growing market in India.