Gas Cylinder Manufacturing Technology
– DSW’s Advanced Design, Production, and Testing Process
1. The design of each DSW gas cylinder is based not only on standard calculation formulas but also on advanced finite element analysis. The computed data are subsequently verified and validated through experimental testing, including strain gauge measurements and other analytical techniques.
2. Following a thorough evaluation of chemical, physical, and mechanical properties—and, where necessary, stress corrosion resistance—all materials (including carbon steel, stainless steel, alloys, and fibre composites) are carefully selected to suit the intended operating conditions.
3. DSW also performs fracture mechanics analysis on the materials used, enabling us to determine the maximum allowable defect size within the cylinder. This allows us to:
· define the non-destructive testing (NDT) thresholds applied on the production line
· ensure the guaranteed fatigue life of the cylinder
· demonstrate that any leakage would occur prior to a potential cylinder burst
4. The surface protection of each gas cylinder is engineered according to the environmental conditions and corrosive substances it may encounter, ensuring long-term durability and safety in service.
DSW Gas Cylinder Manufacturing Process
– From ISO Steel Pipe to Final Quality Testing
1, ISO standard high quality steel pipe
2.Good quality steel pipe test
3, Production line
4, Shrink cylinder bottom
5, Shrink cylinder mouth
6, Heat treatment
7, Normalizing treatment
8,Assemble cylinder neck
9 Automatic cylinder internal polish
10, Cylinder internal polish checking
11, Automatic spraying prodution line
12, Big cylinder, automatic spraying
13, screw valve
14,leakage test
15,Hydraulic Test
16, Permanet expasion test
17, Tensile strength test
18,Yield pressure test
19,bursting test
20, Facory corner
Inside Automatic Gas Cylinder Production Line
A fully automated gas cylinder production line at DSW factory showing robotic forming, welding, heat treatment, and testing processes.
DSW Gas Cylinder Inspection guarantee:
The inner and outer surfaces of the outer containers will be subject to overall sandblasting treatment to meet the requirements of Sa-2.5 standard. When the surfaces of steel plates show the metallic color, a vacuum cleaner will be used to suck off the dust adhered to the surface so as to further ensure the vacuum degree in the interlayer.
Special high-quality perlite is used as the insulation material in the interlayer. The perlite will be treated by using our company’s special process before being in the interlayer. All the internal cylinders, after manufactured, will be subject to the gas-tight and pressure performance tests. Both the internal and outer cylinders will be subject to rigorous Helium mass spectrum leak detection.
The inner containers of the storage tanks will be passivated by overall pickling to meet the cleanliness requirements for dangerous goods. Imported ultraviolet black light lamps will be used to make sure that there is no oil stain and other organic impurities in the inner containers. The inner and outer containers, after cleaning, will be assembled at a time interval less than 2.5 hours. After assembling, the inner containers and interlayers will be filled with nitrogen to protect them from dust and organic impurities, so as to ensure the cleanliness.
The relevant welding seams will be subject to 100% RT non-destructive testing and penetrant testing (PT) according to the technological requirements of storage tank production. High-purity nitrogen (up to 99.999%) will be used to conduct the strength testing. Finally, advanced helium mass spectrometer leak detectors (with precision up to 2×10-9Pa.L/s) will be used to conduct Helium mass spectrometer leak detection.
After the production is completed, all the pipe openings will be opened to carry out nitrogen purging and replacement, so as to meet the oxygen usage standard. After this, all the pipelines and valves will be sealed, and the tanks will be filled with 0.2MPa high-purity nitrogen for protecting the tanks.
Through rigorous testing, DSW demonstrates its commitment to meeting the exacting requirements of ISO standards and DOT regulations. This comprehensive testing process typically encompasses a range of assessments and evaluations, including:
- Design verification and assessment to ensure engineering accuracy and safety.
- Material testing and analysis to confirm suitability and durability.
- Pressure testing to validate structural integrity under operational conditions.
- Leak testing to guarantee gas-tight performance.
- Performance testing across varying operational environments.
- Compliance checks for labeling and documentation requirements.
These procedures ensure that natural gas storage tanks fully comply with applicable standards and regulations, providing assurance of their safety, reliability, and industry compliance.
It should be noted that specific ISO standards and DOT regulations may differ according to the type, purpose, and jurisdiction of the natural gas storage tanks. It is therefore advisable to consult the relevant standards and regulations applicable to your region and sector to ensure complete compliance.