Is16054 2013
Is16054 2013
(Reaffirmed 2019)
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Indian Standard
PERIODIC INSPECTION AND TESTING —
WELDED LOW CARBON STEEL CYLINDERS
EXCEEDING
5-LITRE WATER CAPACITY FOR LIQUIFIED
PETROLEUM GAS (LPG) — CODE OF PRACTICE
ICS 23.060.40; 75.160.30
© BIS 2013
B U R E A UO F INDIAN STANDA
R D S MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR
MARG NEW DELHI 110002
FOREWORD
This Indian Standard was adopted by the Bureau of Indian Standards, after the draft finalized by the Gas
Cylinders Sectional Committee had been approved by the Mechanical Engineering Division Council.
This standard has been formulated as a guide to cylinder fillers for establishing their own cylinder inspection
procedures and standards. It is of necessity, general in nature although some specific limits are recommended. It
should be distinctly understood that it will not cover all circumstances for each individual cylinder type.
Rejection or acceptance for continued use in accordance with these limits, does not imply that these cylinders
are or are not dangerous or subject to impending failure, but represents practice which has been satisfactory to a
cross-section of the industry.
Experience in the inspection of cylinders is an important factor in determining the acceptability of a given
cylinder for continued service. Users lacking this experience and having doubtful cylinders should return them
to a manufacturer of the same type of cylinders for re-inspection.
In the formulation of this standard considerable assistance has been derived from ISO 10464:2004 ‘Gas
cylinders
— Refillable welded steel cylinders for liquefied petroleum gas (LPG) — Period inspection and testing’, issued
by the International Organization for Standardization.
While implementing this standard compliance with statutory regulations shall be ensured.
The composition of the Committee responsible for the formulation of this standard is given in Annex G.
For the purpose of deciding whether a particular requirement of this standard is complied with, the final value,
observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with IS 2 :
1960 ‘Rules for rounding off numerical values (revised)’. The number of significant places retained in the
rounded off value should be the same as that of the specified value in this standard.
IS 16054 : 2013
Indian Standard
PERIODIC INSPECTION AND TESTING — WELDED
LOW CARBON STEEL CYLINDERS EXCEEDING
5-LITRE WATER CAPACITY FOR LIQUIFIED
PETROLEUM GAS (LPG) — CODE OF PRACTICE
1 SCOPE [Link] Inspection — Activity carried out
at defined intervals which includes
[Link] standard specifies the inspection and
examining, measuring, testing or gauging the
testing procedure for the periodic inspection of
characteristics of a cylinder, in line with Gas
transportable refillable welded cylinders for LPG, of
Cylinder Rules, 2004.
water capacity exceeding 5 litres up to and including
250 litres, as per periodicity defined under Gas [Link] — Local corrosion not in excess of 6
Cylinders Rules, 2004. mm diameter and occurring not more frequently than
one in any 500 mm2 of the surface.
It does not apply to cylinders permanently installed in
vehicles. This Code is for mandatory testing of [Link] — Putting cylinder out of service
cylinders and not applicable for repair and until final disposition is defined.
reconditioning of LPG cylinders in use.
[Link] Agency — Corporate body,
[Link] standard refers only to technical approved by Statutory Authority under Gas
suitability and does not absolve the user from legal Cylinders Rules, 2004 on the basis of
obligation relating to health and safety at any stage. combination of appropriate qualification, training,
It has been assumed that the inspection is experience and resources for periodic inspection of
entrusted by appropriately qualified and cylinders.
experienced people or competent persons who have
[Link] Card — Format used for recording
been trained specifically for the task.
2 REFERENCES the details of the cylinders being tested at various
work stations as defined in this standard.
The standards listed in Annex A are necessary
adjuncts to this standard. At the time of publication, 4INTERVAL BETWEEN
the editions indicated were valid. All standards are PERIODIC INSPECTIONS
subject to revision, and parties to agreements
The interval between periodic inspections shall be as
based on this standard are encouraged to investigate
defined by statutory authority.
the possibility of applying the most recent editions
of the standards indicated in Annex A. 5PROCEDURES FOR
PERIODIC INSPECTION
3 TERMINOLOGY
For the purpose of this standard, the definitions given 1. General
in IS 7241 and the following shall apply. The periodic inspection procedures shall be in line with
[Link] — Batch means a lot of 400 cylinders the written scheme approved by statutory authority.
of same capacity received from the cylinder Periodic inspection shall be carried out by approved
5.2 Test Procedures
retesting agency.
owner company. The batch may comprise of
cylinders from different cylinder manufacturers, Procedures for periodic inspection shall essentially
manufactured at different dates. consist of the followiing processes and sequence:
[Link] Person — Person appointed by a) Preparation of cylinders for testing,
the retesting agency and who by a combination of b) External and internal visual inspection,
training, experience and supervision is able to make c) Tare weight checking,
objective judgments on a subject.
d) Valve bung threads inspection,
[Link] Weight — Sum of the tare weight of e) Hydraulic proof pressure test,
cylinder and the maximum weight of the LPG f) External painting for surface protection,
permitted in it.
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IS 16054 : 2013
g) Tare weight checking, suitably with cap to prevent entry of foreign material,
h) Stenciling and markings, water, soap solution inside the cylinder.
j) Valve fixing,
4. External and Internal Inspection
k) Pneumatic test, and
m) Final certification. 1. External Inspection
Since the cylinders received at testing stations are The entire surface shall be inspected by a competent
of different serial numbers and from different person for,
manufactures, the recording and handling of a) dents, cuts, gouges, bulges cracks,
cylinders should be done with proper care to ensure a laminations or punctures,bottom shell
systematic and batch-wise movement of cylinders to thickness, footring bottom clearance applying
avoid mix up resulting into escape of few operations. the criteria for rejection given in Table 1.
On receipt of cylinders, a batch of suitable number b) corrosion, giving special attention to areas
of cylinders preferably one day’s production or where water can be trapped, at the base of
400 cylinders whichever is less, shall be formed the cylinder, the junction between the body
and the cylinders details shall be recorded in route and the footring, the junction between the
card. Route card shall be signed by the competent body and valve guard or shroud,
person. Details for the procedure to be followed for applying the criteria for rejection given in
handling route card are given in 5.14.1. Table 2.
[Link] of Cylinder for Periodic c) other defects (for example, depressed bung
Inspection and Testing or fire damage), applying the criteria for
rejection given in Table 3.
1. Removal of Valve d) integrity of all permanent attachments for
All the cylinders identified for periodic testing shall example, VP ring and footring.
Any cylinder rejected by the competent person shall
be depressurized to atmospheric pressure in a safe be segregated for repair or shall be rendered
and controlled manner at the site approved by unserviceable. The reasons for repair or declaring the
statutory authority. Residual LPG shall be cold flared cylinders as unserviceable shall be recorded along with
by using a suitable adopter and shall be vented the cylinder detials, for example, Sl No., Name of
through a piping manufacturer and Year of manufacture.
1.5 m above the eves of the shed.
2. Internal Cleaning and Inspection
The valve shall be removed carefully after ensuring
complete depressurization. While removing the valve 1. Internal cleaning
a suitable adopter and proper fixture shall be used to Cylinder shall be first cleaned from inside by using
ensure that the cylinder bung threads do not damaged. vaccum pump. After internal cleaning, magnetic bar
2. Degassing of Cylinders shall be used to remove any ferruos particle sticking
at the bottom of the cylinder surface.
The cylinder shall be degassed at a site approved by
statutory authority. Cylinders shall be degassed by 2. Internal inspection
purging it by inert gas, steaming or by filling water The inside of the cylinder shall be visually inspected
till it overflows. In case of degassing by water, the with appropriate internal illumination using low
water shall be retained for not less than 1 h to ensure voltage lamp. Cylinder showing sign of internal
that the cylinder is degassed. After emptying out corrosion shall be evaluated further in accordance with
the water, cylinders shall be kept in inverted Table 2. If mechanical cleaning is required, care shall
position and be tapped gently by non-metallic be taken to avoid damging the cylinder wall. Cylinders
hammer to remove dust, rust or any loose remnants shall be reinspected after cleaning.
in the cylinder. After degassing the inside of LPG
Cylinder shall be checked by explosive meter to 5.5 Tare Weight Checking
ensure that the cylinder is gas free.
After external and internal cleaning, the cylinder shall
3. External Cleaning of Cylinder be checked for tare weight. Cylinder having lost its
Loose coatings, corrosion products, tar, oil or other weight by more than 5 percent of original tare weight
foreign matter on the cylinder surface shall be removed shall be rejected.
by wire brushing, water jet cleaning, caustic soda 5.6 Valve Pad (Bung) Thread Inspection
cleaning or combination of these. Care shall be taken
to avoid damaging the cylinder surface and metallizing. The valve pad thread shall be checked in line with
During cleaning the cylinder opening shall be
covered 2
IS 16054 : 2013
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IS 16054 : 2013
Table 3 Other Defects The gauges shall be callibrated for accuracy against a
[Clause 5.4.1(c)] master gauge at regular interval of minimum once in
Sl Defects Description Rejection a month. The master gauge shall be recallibrated
No. Criteria in accordance with Gas Cylinder Rules, 2004.
(1) (2) (3) (4)
A device shall be fitted in the test equipment to
i) Depressed
Damage to the bung which Rejection
bung in alters the profile of the cylinder all
ensure that no cylnder is subjected to pressure in
excess of its test pressure by more than 10 percent.
ii) Arc or torch cases
Burning of the cylinder base Rejection
in burns metal, a hardened heat affected all cases 5.7.3 Procedure
zone, the addition of extraneous
weld metal, or removal of metal The cylinder shall be tested at the test pressure of
by scarfing or cratering
Excessive general or localized Rejection
2.45 MPa ( 25 kgf/cm2).
iii) Fire
damage in heating of the cylinder usually all Before applying pressure, the extenral surface of the
cases indicated by:
a) Charring or burning of paint1) cylinder shall be in such a condition that any leak can
b) Fire damage of the metal be detected. Cylinder shall be positioned so the welds
c) Distortion of the cylinder are visible during the test.
d) Melting of metallic valve
parts During test the pressure shall be increased gradually
e) Melting of safety cap
till the required test pressure is reached. Then the
1)
In case of superficial charring of paint cylinder may cylinder shall be isolated from the pumping system
be accepted. and the pressure shall be retained for a period of not
less than 30 s. During the test, the cylinder shall be
gently tapped with wooden/nylon hammer near the weld
IS 9121. Prior to checking, the threads shall be joints.
properly cleaned by soft wire brush and ¾" 14
The cylinder shall be thoroughly examined externally
NGT thread cleaning tap.
for any leak. Any reduction in pressure noticed during
The cylinder of which the valve pad thread is worn this retention period or leakage, visible bulge of
out or not meeting the requirements of IS 9121 deformation, sweating on cylinder body shall be treated
shall be rejected. as a case of failure in the test.
7. Hydraulic Proof Pressure Test In case of a leakage in the pressure system, it shall be
corrected and the cylinder re-tested.
1. Preparation of Cylinders
5.7.4 Internal Cleaning and Drying
The external surface of the cylinder shall be clean and
Subsequent to hydraulic proof pressure test, water
completely dry so that any leak can be detected
inside the cylinder shall be completely removed. The
during the test.
internal surface shall be completely dried by dry
2. Test Equipments compressed air and vacuum pump. Internal cleaning
and drying shall be checked by low voltage lamp.
All pipework, flexible tubing, valves, fittings and other
components forming the pressure system of the test 8. Painting
equipment shall be designed to withstand a pressure
of 1.5 times the maximum test pressure of cylinder to 1. General Requirements for Painting
be tested. The design and the installation of the Both the primer coating and enamel paint application
equipment and the cylinders connected to it shall ensure on the external surface of cylinder shall be done by
that no air is trapped in the system. using spraying gun. While applying the primer coating
Equipment shall be either rotary type or invertible and final painting, care should be taken to ensure that
type to faciliate examination of complete surface of the shadow zones, such as, surfaces under footring,
the cylinder. Equipment shall be provided with VP ring, etc, are properly coated.
isolation valve to isolate the system once the test A uniform coating of primer and finish paint shall be
pressure is reached. applied, the combined minimum coat thickness for
Dedicated pressure gauges for each cylinder to read layers of primer and paint shall not be less than 30 µ.
the cylinder test pressure in accordance with relevant For measurement of paint thickness, procedure given
Indian Standard shall be provided. In addition to this in IS 3196 (Part 1) shall be followed.
two numbers of main gauges shall also be provided Cylinder shall be dried as per paint manufacturer’s
on the inlet line of the equiment after the isolation recommendations after application of paint and primer.
valve.
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IS 16054 : 2013
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IS 16054 : 2013
[Link] Segregated for Re-conditioning It is advisable that the allotment of batch number is
or Rendered Unserviceable linked with year and month of testing. For example,
09 A - XX which indicates 09 as the year of re-
1. Re-conditioning
testing, A for the month of January, B for the month of
Cylinders segregated during the visual inspection shall February, etc, and XX is the control number for the
be returned to the owner for re-conditioning or shall month as 1, 2, 3. This procedure provides necessary
be re-conditioned in accordance with IS 13258 as per assistance in monitoring the control on the
the agreement between the owner company and the production as well as for easy access to a certain
re-testing agency. cylinder, if any information is required in future.
2. De-shaping 5.14.2 Certification
Cylinder rendered unserviceable at any stage during After completion of the testing, the re-testing agency
periodic inspection procedure shall be returned to the shall record the details for cylinders accepted and
owner for proper de-shaping or shall be returned after cylinders rejected/recommended for repair as per the
de-shaping as per the agreement between the owner format given in Annex E and Annex F, respectively.
company and the re-testing agency. Complete record
of such cylinders shall be maintained. Re-testing agency shall issue a certificate as per the
Annex D towards periodic testing of cylinders. This
14. Records certificate along with the list of cylinders accepted (see
1. Route Card Annex E) and list of cylinders rejected/recommended
for repair (see Annex F) shall be sent to the cylinder
On receipt of cylinders, a batch of maximum of owning company.
400 cylinders shall be formed.
Recording of the cylinders details shall be done in route 5.14.3 General Record Keeping
card as per format given in Annex C. The format is to The re-testing agency shall maintain records of
be printed on thicker card, as this moves along with inspection reports and test data, calibration data and
the batch, to avoid mutilation and tearing off at the the reports concerning the qualification or approvals
shop floor. Recording of the various stages of periodic of the competent persons. Record shall be maintained
inspection shall be done in the route card. On for all tests and inspections for the cylinders by the
completion of operation/inspection, the concerned re-testing agency. All records pertaining to cylinder
inspecting staff shall sign on the route card with date testing shall be stored in computer and shall be
and forward the same to the next stage. maintained till the life of the cylinder.
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IS 16054 : 2013
ANNEX A
(Clause 2)
LIST OF REFERRED INDIAN STANDARDS
ANNEX B
[Clause 5.10 (c)]
DETAILS OF MARKING ON STAY PLATE
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IS 16054 : 2013
ANNEX C
(Clause 5.14.1)
ROUTE CARD
Name of LPG Cylinder Testing Station :
Owner of LPG Cylinders: ...
Batch No. : .................... Batch Size : .................. Date : ........................
Control No. 1 2 ……….
Sl. No. of LPG cylinders
Name of manufacturer
Date of manufacture (that is, first test date)
Previous test dates
Internal inspection Ok/Rej.
External inspection RT/R/Rej*
(in case of rejection write code for rejection)
Tare weight check Ok/Rej.
Tare weight
Old
New
Final inspection for marking, painting, stenciling
Accepted/Not accepted
Any other defects
*Bulge
RT ——Accepted
E1 for re-testing, R — Repair, Rej. — Rejected.
Burn — E2
The
Dentcode
— Eused
3,
shall be as given below: Dig — E4,
Cut — E5, Pit — E6,
Line General corrosion — E8,
corrosion
— E7 , Loss in tare weight — E10
Bung thread damaged — E9, Bottom clearnace less than limits: E12
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IS 16054 : 2013
ANNEX D
(Clause 5.14.2)
CERTIFICATE ON PERIODIC TESTING OF LPG CYLINDERS
Certificate No: Date :
This is to certify that LPG cylinders having nominal water capacity of liters as per enclosed list 1
have been found acceptable in accordance with IS and hydrostatic test at 2.45 Mpa ( 25.35
Kgf/cm2 ) pressure in accordance with IS 3196 (Part1) : 2006. These cylinders are fitted with self closing (SC)
type LPG valves in accordance with IS 8737:1995 of Type 1 threads (3/4”-14 NGT OF ANSI/CGA V-1-1987)
Batch detials :
Batch No. Batch Size
No. of cylinders accepted :
No. of cylinder rejected :
Duration of testing: From To
The cylinders accepted and tested are as per attached List 1 .
The cylinders rejected/recommended for repair are as per attached List 2.
Re-testing agency signature and seal
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IS 16054 : 2013
ANNEX E
(Clause 5.14.2)
NAME OF TESTING STATION
Certificate No. :
Date
Sl No.: Cylinder No. Name of Manufacturer Date of Manufacture Tare weight
Old New
1
2
3
ANNEX F
(Clause 5.14.2)
NAME OF TESTING STATION
Certificate No. :
Date
SI No.: Cylinder No. Name of Manufacturer Date of Manufacturer Rejected/ Reason
For repair
1
2
3
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IS 16054 : 2013
ANNEX G
(Foreword)
COMMITTEE COMPOSITION
Gas Cylinders Sectional Committee, MED 16
Organization Representative(s)
Petroleum and Explosive Safety Organization, Nagpur SHRI P. B. YEDLA (Chairman)
SHRI D. K. GUPTA (Alternate)
All India Industrial Gases Manufacturers Association, New Delhi SHRI KARAN BHATIA
SHRIMATI VEENA PETER
(Alternate)
Bharat Petroleum Corporation Ltd, Mumbai
SHRI J. VEDAGIRI
SHRI SANJAY PHULLI
Bharat Pumps and Compressors Ltd, Allahabad
(Alternate)
SHRI J. P. SINHA
BOC India Ltd, Kolkata
SHRI P. G. CHOUDHURY
(Alternate)
Everest Kanto Cylinder Ltd, Mumbai
SHRI K. MANOHARAN
SHRI RAMANA VUTUKURU
Hindustan Petroleum Corporation Ltd, Mumbai (Alternate)
SHRI P. M. SAMVATSAR
Indian Oil Corporation Ltd, Mumbai SHRI A. K. KHAMKAR
(Alternate)
International Industrial Gases Ltd, Kolkata SHRI P. P. NADKARNI
SHRI ALOK KUMAR GUPTA
(Alternate)
Kabsons Gas Equipments Ltd, Hyderabad
SHRI RABINDRA N. GHOSH
SHRI S. M. RAMBHAL
Kosan Industries Ltd, Surat
(Alternate)
SHRI DEVENDRA K. GARG
LPG Equipment Research Centre, Bangalore
SHRI NIKHILESh K. GARG
(Alternate)
Mahanagar Gas Limited, Mumbai
SHRI SATISH KABRA
SHRI S. GOPAL AIAH (Alternate)
Maruti Koatsu Cylinders Ltd, Mumbai
SHRI S. K. DEY
SHRI S. B. BOMAL (Alternate)
Ministry of Defence (DGQA), Pune SHRI G. P. GUPTA
SHRIMATI KAROBI MUKHERJEE
Praxair India Ltd, Bangalore (Alternate)
SHRI RAGHUNATH KULAI
Research & Development Estt (Engineers), Pune SHRI ARUN NAYAK (Alternate)
SHRI NITIN J. THAKKAR
Sakha Engineers Pvt Ltd, New Delhi SHRI A. S. SARAN (Alternate)
SICGIL India Ltd, Chennai SHRI J. P. TIWARI
SHRI K. SUDHAKARAN
(Alternate)
Society of Indian Automobile Manufacturers (SIAM), New Delhi
SHRI MILAN SARKAR
SHRI ARINDAM DAS (Alternate)
Steel Authority of India Ltd, Ranchi
SHRI P. K. CHATTOPADHYAY
SHRI A. BASU (Alternate)
Steel Authority of India Ltd, Salem
SHRI AMARJIT S.
Supreme Cylinders Ltd, Delhi KOHLI SHRI
Tata Motors Ltd, Pune FAROOQUE DADABHOY
SHRI R.
PADMANABAN
Tekno Valves, Kolkata (Alternate)
SHRI K. K. GANDHI
SHRI PANKAJ
11 KUMAR KARN
(Alternate)
SHRI DEBASHIS
KARMAKAR
DR B. K. JHA
(Alternate)
IS 16054 : 2013
Organization Representative(s)
Composition of
Organization Low Pressure Representative(s)
Hindustan Petroleum Corporation Ltd, Mumbai Gas Cylinders SHRI ALOK KUMAR GUPTA
All India Industrial Gases Manufacturers Association, Sub-
New Delhi (Convener) SHRI KARAN BHATIA
Committee, SHRIMATI VEENA PETER
Bharat Petroleum Corporation Ltd, Mumbai MED 16:2 (Alternate)
SHRI J. VEDAGIRI
SHRI SANJAY PHULLI
Bhiwadi Cylinders Pvt Ltd, New Delhi
(Alternate)
SHRI MANVINDER SINGH
Hindalco Industries Ltd, Mumbai
SHRI RAJNEESH CHOPRA
(Alternate)
Ideal Engineers Pvt Ltd, Hyderabad
SHRI SUBHANKAR GUPTA
SHRI S. DEVADOSS (Alternate)
In Personal Capacity, (Menon & Patel, 14/1, Mile
SHRI SATISH KABRA
Mathura Road, Faridabad)
SHRI DEEPAK KABRA
Indian Oil Corporation Ltd, Mumbai SHRI(Alternate)
RABINDRA N. GHOSH
SHRI S. M. RAMBHAL (Alternate)
SHRI EBRAHIM M. PATEL
J. R. Fabricators Ltd, Halol SHRI ASHWIN H. MEHTA
SHRI S. SESH KUMAR (Alternate)
Jindal Stainless Ltd, Hisar SHRI L. C. JAIN
SHRI PRAVAIN GOEL (Alternate)
LPG Equipment Research Centre, Bangalore SHRI G. P. GUPTA
SHRIMATI KAROBI MUKHERJEE
(Alternate)
Ministry of Defence (DGQA), Pune
SHRI J. P. TIWARI,
SHRI K. SUDHAKARAN (Alternate)
Petroleum and Explosive Safety Organization, Nagpur
SHRI P. B. YEDLA
SHRI D. K. GUPTA (Alternate)
Sahuwala Cylinders (P) Limited, Visakhapatnam
SHRI A. S. SOMAYAJULU
SHRI S. S. KRISHNA RE (Alternate)
Shri Shakti Cylinders Pvt Ltd, Hyderabad
SHRI D. V. RAJA SEKHAR
SHRI G. NARASIMHA REDDY
Shiv Energy India Ltd, Hyderabad
(Alternate)
Steel Authority of India Ltd, Salem
SHRI R. R. RAJ
SHRI T KALYANASUNDARAM
Supreme Cylinders Ltd, Delhi
SHRI N. K. VIJAYAVARGIA (Alternate)
Tata Iron and Steel Company Ltd, Jamshedpur
SHRI M. L.
SHRI M. C. SADHU (Alternate)
FATHEPURIA DR N.
12 GOPE
Bureau of Indian Standards
BIS is a statutory institution established under the Bureau of Indian Standards Act, 1986 to promote
harmonious development of the activities of standardization, marking and quality certification of goods
and attending to connected matters in the country.
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implementing the standard, of necessary details, such as symbols and sizes, type or grade designations.
Enquiries relating to copyright be addressed to the Director (Publications), BIS.
Amendments are issued to standards as the need arises on the basis of comments. Standards are also reviewed
periodically; a standard along with amendments is reaffirmed when such review indicates that no changes are
needed; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standards
should ascertain that they are in possession of the latest amendments or edition by referring to the latest issue of
‘BIS Catalogue’ and ‘Standards : Monthly Additions’.
This Indian Standard has been developed from Doc No.: MED (16 (1101).