Automatic LPG Cylinder Hydrostatic Testing Machine / LPG Cylinder Production Line

• Max Diameter of Workpiece: 700mm
• Mass Scope of Workpiece: 12.5kg, 33kg, 45kg
• Type: Compression Testing Machine
• Maxcapacity: >1000KN
• Accuracy Grade: 0.5
• Load Way: Electronic Load
• Model NO.: HLT
• Loading Method: Dynamic Load
• Display: Digital
• Control: Computer Control
• Weight: >2000Kg
• Power Source: AC380V
• Oil Cylinder Position: Under
• Irrigation Time: 90 Second
• Pneumatic Pressure: 0.6 MPa
• Hydraulic Test Pressure: 3.2 MPa (Adjustable)
• Name: Automatic LPG Cylinder Hydrostatic Testing Machine
• Oversea Installation: Available
• Warranty: 1 Year
• Transport Package: Standard Seaworthy & Strong Package
• Specification: SGS, ISO
• Trademark: Comflex
• Origin: Wuxi, Jiangsu, China(Mainland)
• HS Code: 85152100
• Production Capacity: 1000sets/Year

Product Description

Automatic LPG Cylinder Hydrostatic Testing Machine

 

 

A. Equipment brief introduction

   Design and manufacture in accordance with the national standard GB/T9251-2011 "cylinder hydrostatic test method and GB 5842-2006" liquefied petroleum gas cylinder "and so on.It's main composed of water pressure testing machine, roller conveyer, hydraulic pneumatic system and control system, etc.
 

B. Characteristic and performance

1, This machine is suitable for LPG cylinder pressure testing, 12 station irrigation, water pressure testing, air pressure drainage step by step to complete.
2, This equipment adopts PLC control, can be realized automatic in the process of LPG cylinder pressure test, irrigation, suppressed, unloading, drainage, out of the bottle,, improving production efficiency.
3, Lower part is equipped with a roller conveyer, installation and use independently, also can be used for conveying line.In order to realize LPG cylinder pressure test process, irrigation, water pressure test, pressure continuous and efficient drainage.
4, Adopts the water pump for water supply, water tank, water can be recycled application.
5, Choosing effective suppression pump to ensure reliable of LPG cylinder pressure test.
6, This machine structure is reasonable, the operation is simple, safe, and convenient maintenance, low labor intensity, test quality standard.
 

 

 

C. Main technical data

1.Testing pressure:3.2MPa
2.Testing efficiency:250-260pcs/h
3.Air pressure:0.6-0.8 MPa
4, Water pressure cylinder model:QGSφ63×280MF_{1     12}pcs
Drainage pressure cylinder model:QGSφ125×250MF_{1     12pcs}
Limited cylinder model:QGSφ80×100MF₂         3pcs
5, Pneumatic solenoid valve      12pcs
6, Voltage,Frequency: 3-phase   380V/50Hz
7,Special Suppression head  12pcs,High pressure pneumatic valve:12pcs,Ball check valves 12pcs,Exhaust valve 12pcs
8,Hydraulic test pump model:2DSY-400/10,
Power:3KW;
Volume:400L/h
Pressure:10MPa
 9, Roller conveying speed:V=0-5m/s
10,Weight:5T
 

D. Structure and function

This machine is made up of  the hydraulic pressure testing machine, roller conveyer, hydraulic pneumatic system and control system.
1. The water pressure testing machine  is composed of frame, water pressure device, the holding device, drainage clamping device, water pump, hydraulic test pump, 1# limit ,2# limit, 3# limit , pneumatic hydraulic parts.Frame panel is equipped with 9 pressure gauge, one of them is precision pressure measuring instrument, used to check test pressure with pressure measuring instrument, the other eight were used to show the actual test pressure and air pressure after the adjustment.
2. The roller conveyer, driven by the motor reducer and gear transmission, to send gas cylinders to set position.
3. Hydraulic pneumatic system: the motor drives the water pump to supply water pressure testing machine, testing water after the compressed air pressure drainage recycling back into water tank.Compressed air through the pneumatic circuit applied to each cylinder, control cylinder action accordingly.
4. The operation control system: the control cabinet of the whole control system, the distribution of each control button on the control panel.Can be realized in the process of liquefied petroleum gas cylinder pressure test, irrigation, suppression, unloading, drainage, and out of the bottle, automatically.
 

E. Installation and debugging

1, According to the specific situation of the workshop, locate equipment installation (roller conveyer top high above the ground is 400 mm).
 

2. connecting power and gas source, checking the water pump, hydraulic test pump, drive
 

3.According to the relevant button, checking whether the parts movement is flexible.

4.Pushing and pull the hand control valve, check wheter the related parts operation is flexible.

5.Sequence of operation:

5.1 pulling out "limit 1", "limit 2", "limit 3" hand control valve stem, "limit 1", "limit 2" "limit 3"  cylinder driving "limit 1", send the cylinder to injection area (if transport too long, inching roller" reverse "button, adjustment in place, the same as below).

5.2 Each location of untest cylinders, starting the irrigation device button, water pressure device tightly sealed cylinder;

5.3 Pressure cylinders, open water pump 2 "and" limit 3 "in the peak;

5.4 Roller forward button, irrigation for the cylinder;

5.5 After cylinders filled with water, the water pump automatically shut down;.

5.6 Water pressure device automatically loosen cylinders;

5.7 Reset "limit 1" hand control valve rod, cylinder "limit 1" reset drive the stop lever down;

5.8 Starting conveyor line, sending the cylinders to the holding area;

5.9 Special crackdown on joint tightening up one by one,holding device sealing cylinder, faster plug with a high-pressure hose;

5.10 Starting testing pump, inlet valve open first for pressure pipe irrigation (also called a secondary irrigation water), water inlet valve and exhaust valve automatically shut down after the expiration of the water (secondary irrigation time controlled by time relay KT1, generally for 10 seconds or so), at the same time,high pressure testing pump open, up to 3.2 MPa after electric contact pressure gauge, pressure valve (8) closed at the same time, the holding 1 ~ 3 min (the holding time is controlled by time relay KT2).The holding time, (8 pcs) the pressure control valve and exhaust valve opening pressure relief at the same time;If the pressure valve and exhaust valve cannot open pressure relief, alarm, manual unloading.

5.11 One by one quickly remove the high pressure hose, then spiral out them one by one on joint;

5.12 Insert the drain;

5.13 Starting the drainage device button, the drainage pressure device tightly sealed cylinder;  

5.14 Pulling out "inlet" hand control valve stem, compressed air into the cylinders, intake and drainage;

5.15 Gas cylinders after completion of drainage, drainage clamping device loosen cylinders;

5.16 Reset "limit 2" hand control valve rod, cylinder "limit 2" reset drive the stop lever down;

5.17 Starting the conveyor line, send the  tested cylinders to the drainage station, behind a batch of cylinders and following up, when checked the cylinder base hit "limit 3" stop lever, conveyor line stop, remove checked cylinders, to complete a working cycle.

Note:
1. The functions of two pcs of time relays
1.1 KT1 time relay is specially used to control the secondary watering time (i.e. the opening interval time of the water supply valve and the pressure test pump).
1.2 KT2 time relay is used to control the pressure holding time.
 2. "Limit 1" and "Limit 2" cylinders are at the working status only when it starts up to work (i.e. it is at working status).
3. Adjust the steel cylinder to the determined position:
3.1 The lower structures of watering and draining out compact units have the forced positioning function, which can remove the error on a certain range.
3.2 There is two pcs of guard rails at rear and front of machine so that the cylinder goes ahead without deviation.
 

F. Matter Need Attention

1. Ensure the power supply and the gas supply smooth, prohibit to drive the motor in reversal so as to damage the components.
2. We prepare the 2-2.5M³ compression air storage tank to ensure the gas supply pressure 0.5-0.6Mpa. The main pipe and its interface of air inlet pipe should be more than G1", ensure the gas supply flowing volume is enough.
3. Keep water clear in water tank, without any dirty, without any float sundries. If there is, remove the float drifting sundries, in case it blocks the pipeline and effect the normal test.
4. Add 20# machinery oil onto the standard level for reducer, often check it.
5. Before shift over, pls press the "stop" button, cut off the power supply and gas supply.
6. There is safety protection for earthing in machine.
7. If you find there is abnormal on the indication of pressure-proof test actual pressure measuring meter when you start up the first batch gas cylinder testing every day, please calibrate it by the precision pressure measuring meter.
8. When equipment runs normally, pls close tightly the valve access to the precision pressure measuring meter (i.e. the calibration valve, also named as pressure meter switch).
 

G.Maintenance

1. Add 20# machinery oil to lubricate the both side sliding blocks of pressure test pump for each shift. Add the 20# machinery oil into the reducer tank and the driving reducer meeting to requirement. After 36 hours, change one time. Then change oil one time for each 500 hours.  
2. Ensure the equipment is clear without any dirty. If the pressure test pump is not used for long term, pls add the anti-corrosion water. After 3~5 minutes when start up machine, pls drain out the water storage in pipe of machine.
3. Pls add the 22# steam machinery oil into the triple oil forge device, and clean up the air filtration water piling. Add the oil into the roller table both side bearings twice for each working shift, ensure its lubrication.
4. Calibrate the pressure meter as stipulation.

 

 

Complete LPG gas cylinder production line

I. Machinery list:

No.	Description	Size&Specis	Unit
I	Main Equipment
1	Hydraulic Press	500T	set
2	De-colier and punching machine for small round sheet cutting from big sheet (material preparing for shell)	XL-2	set
3	Material cutting mould on hydraulic press		set
4	63ton hydraulic logo stamping machine	63T	set
5	Shell drawing machine	200/300	set
6	Shell forming mould	LS-2	set
7	Automatic trimming machine	QK-4	set
8	End dish necking machine	SK-3	set
9	Cleaning machine	QL-5	set
10	Hole punching machine	CK-3	set
11	Valve Seat Welding Machine	HP-2	set
12	Shroud welding machine	HZ-1	set
13	Bottom base welding machine	DZ-1	set
14	Assembling Machine	ZH-1	set
15	Option NO.1:Circumferential Seam welding machine	HJ-3	set
	Option NO.2:Circumferential seam welding machine	Single head MAG	set
16	Annealing furnace with burner	TW-1	set
17	Hydrostatic Testing Machine	SY-6	set
18	Shot blasting machine	QYP15	set
19	Spraying line	JH-2	set
20	Valve mounting machine	JF-2	set
21	Air Leakage Testing Machine	Cm-2	set
22	Printing machine	ZS-2	set
23	Roller conveyor line		m
24	Curve Convoyer		m
25	Conveyor line power		set
26	Motorized testing pump		set
27	Cylinder drying machine		set

 

II	Equipment For Accessories Manufacturing Equipment
28	Punching machine/power press	25T	set
29	Punching machine/power press	63T	set
30	Punching machine/power press	100T	set
31	Bottom base hydraulic forming machine		set
32	Shroud upper R hydraulic forming machine		set
33	shearing machine	4mm*1.5m	set
34	Shearing machine	4mm*2.5m	set
35	Printing machine	GZ-2	set
36	Coding machine	BM-1	set
37	Shroud rolling machine		set
38	Bottom base rolling machine		set
39	Shroud mould		set
40	Bottom base mould	DM-2	set
41	Bottonm base welding machine		set

 

III	Auxiliary Equipment
42	Air compressor (screw)	10/0.8	set
43	Air compressor (piston)	2.0/3.0	set
44	Air storage tank	1m3/3Mpa	set
45	Air storage tank	2m3/1Mpa	set

 

IV	Testing Equipment
46	X-ray detecting equipment	2505C	set
47	Mechanical property testing equipment	WES-600B	set
48	Burst pressure testing equipment		set
49	Ultrasonic wall thickness testing equipment		set

 

II. Description for each equipment:

1. De-coil and punching machine for small round sheet cutting from big sheet(material preparing for shell)
Technical data:
Raw material specifications:
Plate Thickness:2-4mm    Width of plate:Max.1170mm 
ID of steel coil:450-800mm    OD of steel coil:Max.1800mm  Weight of steel coil:Max.25T
Coil blanking specification:Ø370-Ø615mm   Blanking period:12s/time including auxiliary time
 
Hydraulic machine technical data
Motor power:46KW      Norminal capacity:6300KN   Max.working pressure:25Mpa
Slide travel speed:120mm/s  

Working table size:2500mm(front+back)*1500mm(left*right)
Weight of decolier:12T   Weight of hydraulic press machine:23T

2.63ton hydraulic logo printing machine
 
3. Hydraulic press drawing the head
Press the round sheet into a shell with dies.
  
4. Automatic trimming machine
This machine is reliable, easy to operate.
Technical data
Motor power:5.5KW   Air pressure:0.6Mpa   Trimming time:20s   Weight of machine:1.5T
 
5. End dish necking machine
Technical data
Motor power:4.5-11kw  Air pressure:0.6Mpa  Thickness of plate:1-10mm  

Necking head diameter:150-1200mm Necking time:10-50s (adjustable)
Weight of machine:1.5-3T

6.Cleaning machine
Technical data
Motor power:1.5kw   Polishing motor power:1.5kw*2  Air pressure:0.6Mpa 
Polishing wheel feed range:0.2-20mm  Efficiency:180Pcs/hour  Weight of machine:1.2T
 
7.Hole punching machine
Punch the hole on head of the cylinder
Technical data
Motor power:5.5kw  Punching speed:180Pcs/hour  Weight of machine:1.5T
  
8.Valve Seat  Welding Machine
To complete the welding of valve seat ring joints. Ensure uniform forming, good appearance, weld penetration and weld width meets the technological requirements, the clamping is convenient. Using submerged arc welding technology, girth welding at one time
Technical data
Rated voltage:220V Motor power:0.25kw Air pressure:0.6Mpa

 

9.Bottom base welding machine
Complete cylinder base girth automatic welding. To ensure concentricity, uniform forming, good appearance, weld penetration and weld width meet the technological requirements, the clamping is convenient. CO2 gas shield welding process, complete in one time welding.
Technical data
Current:AC380V+N    Motor power:0.55kw   Air cylinder pressure:0.5-0.7Mpa
  
10.Protection enclosure welding machine
Complete cylinder base girth automatic welding. To ensure concentricity, uniform forming, good appearance, weld penetration and weld width meet the technological requirements, the clamping is convenient. CO2 gas shield welding process, complete in one time welding.
Technical data
Rated voltage:AC380V  Motor power:0.55kw  Air cylinder pressure:0.5-0.7Mpa 
  
11.Assembling Machine 
To assemble both halves of the cylinder together and get ready for welding
Technical data
Cylinder diameter:250mm     Air cylinder pressure:0.5-0.7Mpa
 
12.Circumferential Seam welding machine

Option NO.1:
Technical data

Voltage:AC380V+N  Motor power:0.55KW  Rotation speed:Max.10rpm/min (adjustable)  
Motor power:0.55kw
 
Option NO.2:
Technical data
This machine is applicated to automated MAG circumferential welding for LPG cylinder,fire extinguisher bottle,etc.
Welding Length:Max.1500mm   Ø:250-400mm   Thickness:2.5-6mm
This machine price include 1 set panasonic welding machine(Model:GL3-500A),1 set cooling water device,welding seam tracker.
Producing capacity:250 pcs/8 hrs

13. Gas car-bottom heat treating furnace machine
This furnace is designed to anneal LPG cylinders by applying flame from gas burner on the cylinders. It composes, burner, flaming chamber, smoke collector, rails, chain roller, exhaling system.
It feature includes, adjustable time, self-control thermometer, perfect heat treatment result and fire off pollution.
 
Technical data
Producing efficiency:75pcs/hr  Feeding type:Chain drive/cylinder feeding
Cleaning size:Ø320*700mm------Ø420*1250mm
Dimension:(L*W*H):12500*1390*1560mm   removable transport

 

14. Hydrostatic Testing Machine
The machine is special for steel cylinder of liquefied gas cylinders,applicable to manufacturers and testing station for wuthstand voltage test on cylinder.Irrigation,pressurization,pressure,maintaining centralized control and automatic pouring completed by using water pump,equipped with a water tank,water can be recycled.
Technical data:
Pneumatic pressure:0.6Mpa                    Motor power:3kw 
Hydrostatic test pressure:3.2Mpa             Weight:1.1T
 
15. Cylinder drying machine
The equipment is used for drying the bottle cylinder after water pressure test.
 
16. Shot Blasting Machine
Shot Blasting Machine for LPG Cylinder are predominantly used to clean LPG/CNC/GAS cylinder in a continuous through feed process, remove remains of casting sand and cores, rust, old paint, visible signs of welding, eliminate surface stress, improve the fatigue strength of the workpiece, increases workpiece film adhesion of the paint job, and ultimately achieve the aim of improving the quality of surface and internal, prepare for surface protection (coloring, enameling, galvanizing, etc.).
Technical data
Produing efficiency:80-120pcs/hr        Shot blasting machine:2 sets
Hoist motor power:2.2KW                    Total power:31.2KW  
Weight:16T                                           Workpiece size:Ø320mm*680mm
Machine dimension:(L*W):7885*2460mm

17. Spraying production line
The spraying producing line for U track,using electric or natural gas,fuel oil,coal heating,hot air circulation,the allocation of fixed automatic spray gun 4,manual gun 1.Spraying powder or paint on the steel cylinders apperance.The cylinder into the oven drying after spraying

Technical data
Working voltage:380V 50HZ      Air pressure:0.4-0.6Mpa 
Total power:15KW             Working efficiency:180Pcs/jr
 
18. Valve mounting machine
The equipment is suitable for the liquefied petroleum gas cylinder angle value installation and use,it absorbs the domestic and foreign advance technology,using electrical control,pneumatic clamping,torque adjustable device,when reaching a certain torque,and go to the specificed direction after the automatic shutdown.The machine operation and flexible,convenient and safe
Technical data

Motor power:2.2KW                           Motor speed:1400r/min 
Work spindle speed:15.5r/min            Working air pressure:0.5-0.6Mpa
Consumption per hour:1.14m3           Clamping cylinder stroke:120mm
Rotation speed ration:1:59                  Weight:0.9T

19. Leakage Air Test Machine
The device for cylinder do tightness test with,composed of a water tank,a lifting cylinder,a bottle feeding machine,electric control part and other parts,work a bottle feeding mechanism of automatic cylinder will send to be test station,a lifting cylinder will fall into the water.the operating personnel rotation observations of the cylinder is not leaking cylinder,after the test and the cylinder out of water,a loop end.This machine is reasonable in structure,simple operation and maintenance.
Technical data
Air pressure:0.6Mpa                    Testing air pressure:2.2Mpa  
Holding pressure time:60s            Weight:1.8T

III. Machinery picture:
 

Automatic circumferential welding machine


 

Shot blasting machine



Powder coating line


 

IV. Successful projects:

1. TK Group in Bangladesh


2. Hangzhou Yuhang Zhangshan Steel Cylinder Co.,Ltd.It is 3rd biggest LPG gas cylinder manufacturer in China, daily output is 12000pcs including all sizes from 2kgs to 50kgs.


3. TPA is manufacturing extremely high quality LPG cylinders for North America, European,UK and Australia. http://kelly-huang71.en.made-in-china.com, we supplied automatic welding line for their China plant in Dongguan. Now we are building new LPG gas cylinder factory in Vietnam, Hangphone, at the end of July, 2017, it will be set up and commissed.


4. Mintai is a newly set-up LPG gas cylinder manufacturing factory in China, the reason we took you there is to see different equipment, especially the online x-ray testing device for the size more than 25kgs which is required 100% X-ray testing in China. The machines for handle and bottom base are samiliar with the ones we will supply to you

 

5: Shandong Huanri Group co.,Ltd.,ho http://kelly-huang71.en.made-in-china.com, they are biggest and strongest cylinder manufacturer in China, they bought our machines both for 12.5 and15kgs manufacturing and 50kgs manufacturing. 


6.AYGAZ in Turkey,  kelly-huang71.en.made-in-china.com.tr 


7. Manchester Tank from USA