CENTRAL MARKS DEPARTMENT-III Our Ref : CMD-III/16:15490 30 Oct 2006

Subject : SULPHIDE STRESS CRACKING RESISTANCE TEST ON CNG CYLINDERS AS PER IS 15490:2004 This is further to CMD Note of even no. dated 20 March 2006 regarding frequency to carry out above test on each heat/cast. The issue has been discussed during Gas Cylinder Sectional Committee ME 16 held on 6-7 July 2006 at Hyderabad. Extracts from the minutes of the meeting are reproduced below: IS 15490:2004 Cylinders for on-board storage of compressed natural gas as a fuel for automotive vehicles M/s EKC submitted the details of 11 samples got tested by them for sulphide Stress Cracking Resistance Test and it was observed that all the 11 samples have passed the requirements. Therefore, the committee noted that further testing for each heat/cast as given in Scheme of Testing and Inspection for BIS Certification is not required. BIS may like to amend the Scheme of Testing and Inspection accordingly. In view of above, it is proposed that Sulphide Stress Cracking Resistance Test on CNG Cylinders as per IS 15490:2004 may not be insisted on each heat/cast and shall be carried out at the time of approval of material or whenever there is change in raw material or required by BIS for any specific reasons. Accordingly, existing STI DOC:STI/15490/1, May 2005 has been revised as DOC:STI/15490/2, December 2006 (copy enclosed) and would be implemented w.e.f. 1 Dec 2006. ROs/BOs are requested to inform the licensees under their jurisdiction about the revised STI and ensure implementation w.e.f. 1 Dec 2006.

(Rajeev Sharma) Sc.D (CMD-III) DCM-III DDGM ALL ROs/BOs

DOC:STI/15490/2 Dec 2006 SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF FOR ON-BOARD STORAGE OF COMPRESSED NATURAL GAS AS A FUEL FOR AUTOMOTIVE VEHICLES ACCORDING TO IS 15490:2004 (Third Revision) 1. LABORATORY A laboratory shall be maintained which shall be suitably equipped and staffed where different tests given in the specification shall be carried out in accordance with the methods given in the specification. 2. TEST RECORDS - All records of tests, inspection and calibration shall be kept in suitable forms approved by the Bureau. 2.1 All testing apparatus/measuring instruments shall be periodically checked and calibrated and records of such checks/calibration shall be maintained. 2.2 Copies of any records and other connected papers that may be required by the Bureau shall be made available at any time on request. 3. QUALITY CONTROL It is recommended that, as far as possible, Statistical Quality Control (SQC) methods may be used for controlling the quality of the product during production as envisaged in this Scheme [See IS 397(Part I)::2003, to IS 397(Part 4):2003]. 3.1 In addition, effort should be made to gradually introduce a Quality Management System in accordance with IS/ISO 9001:2000. 4. STANDARD MARK The Standard Mark, as given in Column (1) of the First Schedule of the license, shall be stamped on a non-detachable and non-pressure part of the cylinders provided always that each cylinder, so marked, conforms to every requirement of the specification. 4.1 Each cylinder shall also be stamped with the following on formed neck where thickness of metal is greater than the design minimum and where it is adequate for marking to be carried. Suitable areas of marking shall be determined by sectioning a prototype cylinder by any suitable method acceptable to the statutory authority. a) b) c) d) e) f) g) h) i) j) k) Serial number ; Identification of manufacturer; Month and year of hydrostatic test, such as 06-2004; Test pressure, in kgf/cm2 Number of this standard; The tare weight, in kg, and nominal water capacity, in liters; Inspectors official mark; The design charging pressure in kgf/cm2 at 15C; ONB-CNG to show the intended application; and DO NOT USE AFTER XX/XXXX where XX/XXXX identifies month and year of expiry; and Licence Number (CM/L).

DOC:STI/15490/2 Dec 2006 4.2 The characters in marking shall normally be at least 6 mm in height.. The indentation shall not be of excessive depth. 5.0 BATCH -All cylinders, not exceeding 202 in number subjected to heat treatment in the same manner, and constructed from steel of similar analysis and made by the same steel manufacturer, in a furnace as per clause 5.7 of IS 15490:2004 shall constitute a batch. 5.1 The identity of each batch shall be separately maintained.

6. LEVELS OF CONTROL - The tests, as indicated in Table 1 attached and at the levels of control specified therein, shall be carried out on the whole production of the factory which is covered by this scheme and appropriate records and charts maintained in accordance with paragraph 2.0 above. All the production which conforms to the Indian Standards and covered by the license shall be marked with certification mark of the Bureau. 6.1 The test shall be carried out under the supervision of an inspecting officer of the Bureau and the cylinders marked with the ISI Mark. 6.2 A certificate as per Annexure B shall be issued by the Inspecting officer in respect of every batch of cylinders marked with ISI Mark. 7.0 MATERIALS - The steel used in the manufacture of cylinders shall conform to the requirements given in clause 5 of IS 15490:2004. A certificate for each heat number shall be obtained from the steel maker giving the analysis of the steel. The inspecting authority shall be given the opportunity of making an independent check analysis, if necessary. The manufacture of gas cylinders should establish means to identify the cylinders from the casts of the steel from which they are made. 7.1 Maximum tensile strength of steel shall be limited to 1100 MPa and hardness should not exceed 330 BHN. In case tensile strength exceeds 950 MPa (design value) materials shall be subjected to sulphide stress cracking resistance test as given in 8.3.4 of IS 15490:2004. 8.0 DESIGN AND FABRICATION In all respect of design and manufacture, the cylinder shall conform to clause 6 and 7 of1 IS 15490:2004. 9.0 HEAT TREATMENT - After manufacture & before the hydraulic test is applied, all cylinders shall be heat treated as per clause 5.7 of IS 15490:2004. A complete record of the heat treatment cycle shall be maintained. 10.0 Cylinders which have been rejected due to a)Ultrasonic detection, b) Defective threads, c) Leakage at hydrostatic stretch/proof test or pneumatic leakage test should be destroyed to the satisfaction of inspecting officer by cutting off the defective portion of the cylinder to make it unserviceable. 11.0 REJECTIONS A separate record shall be maintained giving information relating to the rejection of the production not conforming to the requirements of the specification and the method of its disposal. Such material shall in no circumstances be stored together with that conforming to the specification. 12.0 SAMPLES The licensee shall supply, free of charge, the samples required in accordance with the Bureau of Indian Standards (Certification) Regulations, 1988, as subsequently amended, from the factory or godowns. The Bureau shall pay for the samples taken by it from the open market.

DOC:STI/15490/2 Dec 2006 13.0 REPLACEMENT Whenever a complaint is received soon after the goods with Standard Marks have been purchased and used, and if there is adequate evidence that the goods have not been misused, defective goods or their components are replaced or repaired free of cost by the licensee in case the complaint is proved to be genuine and the warranty period (where applicable) has not expired. The final authority to judge the conformity of the product to the Indian Standard shall be with the Bureau. The firm shall have own complaint investigation system as
per IS 15400.

13.1 In the event of any damages caused by the goods bearing the Standard Mark, or claim being filed by the consumers against BIS Standard Mark and not conforming to the relevant Indian Standard, entire liability arising out of such non conforming product shall be of licensee and BIS shall not in any way be responsible in such cases. 14.0 STOP MARKING The marking of the product shall be stopped under intimation to the Bureau if, at any time, there is some difficulty in maintaining the conformity of their product to the specification, or the testing equipment goes out of order. The marking may be resumed as soon as the defects are removed under intimation to Bureau. 14.1 The marking of the product shall be stopped immediately if directed to do so by Bureau for any reason. The marking may then be resumed only after permission by the Bureau. The information regarding resumption of markings shall also be sent to the Bureau. 15.0 PRODUCTION DATA The licensee shall send to BIS as per the enclosed proforma-1 to be authenticated by a Chartered Accountant a statement of quantity produced, marked and exported by him and the trade value thereof at the end of each operative year of the licence. Table 1

DOC:STI/15490/2 Dec 2006 IS 15490:2004 CYLINDERS FOR ON-BOARD STORAGE OF COMPRESSED GAS AS A FUEL FOR AUTOMATIVE VEHICLES TABLE 1 LEVELS OF CONTROL (Para 6 of the Scheme of Testing and Inspection) TEST DETAILS Requirement Test Methods Clause 5. MATERIAL Steel Billets/Seamless Tubes/Plates Reference LEVELS OF CONTROL Lot Size Fre- Remarks que ncy Each heat These tests will not be necessary if a certificate is supplied by the steel maker giving analysis of the finished steel and certifying that the steel conform to the requirements specified in the standard (see also cl.7 of the scheme of Testing & Inspection) In case the consignment is covered by a certificate showing its conformance to the specification, further testing is not necessary.

Cl.

No. of samples One

5.5 IS 15490 and Table 3

Material for neck ring

As per design/ Drawing

Two

Each consignme nt received

7.

Manufacture General Examination before closing in operation Cylinder shape and wall thickness Surface defects Out of roundness Mean Diameter Straightness Water capacity Cylinder neck , threads and fittings Heat treatment

7.1 7.2 7.3 7.4 7.7 7.8 7.9 7.5 7.6 5.7

IS 15490 -do-do-do-do-do-do-do-do-do-

Each cylinder -do-do-do-do-do-do-do-do-do-

5.7

DOC:STI/15490/2 Dec 2006 IS 15490:2004 CYLINDERS FOR ON-BOARD STORAGE OF COMPRESSED GAS AS A FUEL FOR AUTOMATIVE VEHICLES TABLE 1 LEVELS OF CONTROL (Para 6 of the Scheme of Testing and Inspection) TEST DETAILS Requirement Test Methods Clause 10.2 Hydraulic test Hydrostatic stretch test Proof pressure test Ultrasonic examination Leakage test Hardness test Batch Tests Tensile Test Bend Test Impact Test Sulphide stress cracking resistance test 10.2.2 10.2.1 Reference IS 15490 -do-doLEVELS OF CONTROL Lot FreRemarks Size quency

Cl.

No. Of samples -

Each cylinder -do-do-

10.3 10.4 10.1 9

10.3 & -doAnnexure D 10.4 -do10.1 -do8.3.1 8.3.2 8.3.3 8.3.4 -do-do-do-doOne

-doEach Batch -do-doThis test shall be carried out at the time of proto type testing, any change in the material used for manufacture of cylinders or when required by BIS for specific reasons. (Ref also 7.1 of STI) -do-

8.3.4

Four Three One

Pressure cycling and burst test Note : 1.

9.3

-do-

One

In the event of failure of sample in any requirements, re-testing or reheat treatment and re-testing shall be carried out as per provision given in clause 9.2 of IS 15490:2004. In case of new design as per details given in clause 8.1 and change of design as per Table 4, prototype testing shall be carried out as per clause 8.2 in presence of BIS officer for type approval and BIS shall issue type approval certificate as per Annex A.

2.

DOC:STI/15490/2 Dec 2006

ANNEX A

TYPE APPROVAL CERTIFICATE

Issued by

BUREAU OF INDIAN STANDARDS

As per IS 15490:2004 for SEAMLESS STEEL GAS CYLINDERS FOR ON-BOARD STORAGE OF COMPRESSED NATURAL GAS AS A FUEL FOR AUTOMOTIVE VEHICLES

Approval No:..

Date:..

Type of cylinder:. [Description of the family of cylinders(Drawing No.)which has received type approval] Ph.bar, Dmin.mm, Dmax...mm, d.mm

Shape of base:.,

b..mm

L mi...mm, L max .mm, Vmin litre, Vmax ....litre Material and heat treatment:.. Material and characteristics: MaterialRe.MPa.R8MPa Manufacturer (name & address) ...

Date;. Place:

(Signature of Quality Control Incharge) (Name of Manufacturer)

Encl :

(Signature of BIS Officer)

Copy of test report of cylinders tested for type approval.

DOC:STI/15490/2 Dec 2006

ANNEX B

ACCEPTANCE CERTIFICATE For

SEAMLESS STEEL CYLINDERS FOR ON-BOARD STORAGE OF COMPRESSED NATURAL GAS AS A FUEL FOR AUTOMOTIVE VEHICLES Certificate No. .. A consignment of.cylinders consisting of ..test batches has been inspected and tested.according to IS 15490: 2004 Manufacturers No: Owners No1).. Owner/Manufacturer 2): to. to Manufacturer Order No:

Address:.. Country:. Date:...

TECHNICAL DATA Water capacity, V: Nominal 1))..litre Minimum 1) ..litre Test pressure , Ph :.bar Working pressure at 15C, PW :bar Maximum filling charge1) .kg Nominal length:.mm (without cap and without valve) Outside diameter, Do:.mm Minimum wall thickness.a :...mm Drawing No:.Approved vide CCEs letter No: ..dated Colour of Body __________________________ Material: Manufacturername, /Specification, /designation and grade: Suppliers certificate/No/Date.. Specified analysis 3): Percent, Max: Percent, Min: Heat treatment : Stamp markings3) : ________________
1)

Si

Mn

(P+S)

If required by customer. Delete as applicable. 3) To be quoted or drawing to be attached

2)

DOC:STI/15490/2 Dec 2006 ACCEPTENCE TESTS

1. Measurements taken on one representative cylinder of the batch 4) Test No. or Batch No. or Cylinder No. Covering Serial Noto Water Capacity, litre Mass Empty, kg Minimum Measured Thickness, mm Wall Base Outside Diameter, mm

2. Mechanical Tests4) Bend or Flattening Test 180o Without Cracking Sr. No . Re sul t Sr. No. Res ult Hydrauli c Test Leakage Test

Test No. or Cylind er No.

Cast No.

Tensile Test

Hard ness Elong ation (A) %

Impact Test Charpy(V)oC. Direction

Yield Stress (Rea ) MPa

Tensil e Stren gth (Rm) MPa

HB Averag e J/cm2 Mini mum J/cm2

This is to certify that the cylinders covered by this Acceptance Certificate have passed the hydraulic pressure test and all the other tests as required in 10 of IS 15490 :2004 and they are in accordance with this standard. Remarks: Date (Signature of Quality Control Incharge) Name of Manufacturer _____________________
4)

(Signature of BIS Officer)

Need not be filled in if test reports are attached.