PM/ IS 7285 (Part 2)/ 1/ Jan 2019

PRODUCT MANUAL FOR

REFILLABLE SEAMLESS STEEL GAS CYLINDERS -
QUENCHED AND TEMPERED STEEL CYLINDERS WITH
TENSILE STRENGTH LESS THAN 1 100 MPa (112 kgf/mm²)
ACCORDING TO IS 7285 (Part 2):2017

This Product Manual shall be used as reference material by all Regional/Branch Offices &
licensees to ensure coherence of practice and transparency in operation of certification under
Scheme-I of Bureau of Indian Standards (Conformity Assessment) Regulations, 2018 for
various products. The document may also be used by prospective applicants desirous of
obtaining BIS certification licence/certificate.

1. Product : IS 7285 (Part 2):2017

Title : REFILLABLE SEAMLESS STEEL GAS CYLINDERS -

QUENCHED AND TEMPERED STEEL CYLINDERS
WITH TENSILE STRENGTH LESS THAN 1100 MPa
(112 kgf/mm²)

No. of amendments : Nil

2. Sampling Guidelines

a) Raw material : Steel - Clause 5 of IS 7285 (Part 2)

b) Grouping Guidelines : Each variety of Cylinders shall be tested for GoL/CSoL.

[Please see clause 9.1 of IS 7285 (Part 2) also].

c) Sample Size : As per clause 9.2 of IS 7285 (Part 2)

3. List of Test Equipment : Please refer Annex - A

4. Scheme of Inspection : Please refer Annex - B

and Testing

5. Possible tests in a day : Please refer Annex - C

6. Scope of the Licence : Please refer Annex - D

BUREAU OF INDIAN STANDARDS

Manak Bhawan, 9, Bahadur Shah Zafar Marg,
New Delhi – 110002

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 PM/ IS 7285 (Part 2)/ 1/ Jan 2019

ANNEX A

List Of Test Equipment

Major test equipment required to test as per the Indian Standard

Sl. Tests used in with Clause Reference Test Equipment

No.
Test Clause No.
1 Depth of Concave bottom Clause 6.4 Depth Gauge
2 Neck threads Clause 6.8 Thread inspection gauges
3 Valve Fitting Clause 6.6.3 Torque Wrench
4 Wall Thickness Clause 7.2 Ultrasonic Thickness Gauge
5 Surface Defects Clause 7.3 Ultrasonic Thickness Gauge
6 Out Of Roundness Clause 7.5 Vernier Calliper or Outside Micrometre or Set
of Outside Calliper and Steel Rule
7 Mean Diameter Clause 7.6 Pi tape
Outside Calliper with Steel Rule
Micrometre
8 Straightness Clause 7.7 Feeler Gauge
Steel Rule/Straight Edge
Steel Rule/Straight Edge
9 Verticality Clause 7.8 Fixture for measuring Verticality
Feeler Gauge
Steel Rule/Straight Edge
10 Stability Clause 7.9 Vernier Calliper
Scale
11 Water Capacity Clause 7.11 Digital Electronic Balance
12 Hydraulic Bursting Test Clause 10.5 Pressure Gauge
Test Fluid Reservoir
Tank for measurement of fluids
Pressure/Time curve recorder
Vent or air release valve
Test well
High Pressure Pump
13 Pressure cycling Test Clause 9.2.3 Pressure Gauge
Temperature Sensor
Non-Corrosive Liquid
Pressure cycling test set up
Stop Watch
14 Base Check Clause 9.2.4 Magnifying Glass
15 Tensile Test Clause 10.2 Universal Testing Machine
Vernier Calliper
Micrometre

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 PM/ IS 7285 (Part 2)/ 1/ Jan 2019

16 Impact Test Clause 10.3 Impact testing Machine

Deep Freezer/Dry ice
Thermometer– Digital / Glass type
Profile Projector/Go-No Go gauges
17 Bend Test Clause 10.4 Universal Testing Machine

18 Hydrostatic Stretch Test Clause 11.2 Overflow

Hydraulic Line Valve
Water Jacket Water Supply
Method
Jacket Filling Valve
Air Bleed Valve
Pump
Relief device
Drain
Calibrated Burette
Priming Valve
Pressure Gauge
Weighing Balance – Electronic
Non- Water Water Tank
Jacket Bleed Valve
Method
Pressure Gauge
Pump
Weighing Balance Electronic
19 Hardness test Clause 11.3 Hardness Testing Machine (Brinell or
Rockwell)
20 Leakage Test Clause 11.4 Pressure Gauge
Tank with Lighting Arrangement
21 Colour Identification Clause 12 Coating thickness Gauge
22 Sulphide Stress Clause 9.2.5 Universal testing machine
Cracking Resistance Test Distilled Water
Sodium Acetate tri-hydrate
Acetic Acid
23 Ultrasonic Examination Clause 7.4 Ultrasonic Testing Machine
Standard Piece for UT
Ultrasonic Flaw Detector

The above list is indicative only and may not be treated as exhaustive.

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 PM/ IS 7285 (Part 2)/ 1/ Jan 2019

ANNEX B

Scheme Of Inspection And Testing

1. LABORATORY - A laboratory shall be maintained which shall be suitably equipped (as per the
requirement given in column 2 of Table 1) and staffed, where different tests given in the
specification shall be carried out in accordance with the methods given in the specification.

1.1 The manufacturer shall prepare a calibration plan for the test equipments. The following
equipments shall be calibrated at a frequency shown against each and records kept:

1.1.1 Tensile Testing Machine - Once in a year

1.1.2 Impact Testing Machine - Once in a year
1.1.3 Pressure Gauges - At least once in a month
1.1.4 Pyrometer used for heat treatment furnace - Once in six months

2. TEST RECORDS – The manufacturer shall maintain test records for the tests carried out to
establish conformity. Records of all the tests made at the cylinder manufacturer’s work shall be kept
for the life time of the cylinder and copies of test certificates shall be forwarded to the purchaser of
the cylinder and the inspecting authority.

3. LABELLING AND MARKING - As per the requirements of IS 7285 (Part 2):2017.

4. BATCH - For the purpose of this scheme, a quantity of upto 200 cylinders plus cylinders for
destructive testing of the same nominal diameter, thickness and design, made successively from the
same steel and subjected to the same heat treatment for the same duration of time shall constitute a
Batch.

4.1 The identity of each batch shall be maintained. Each batch conforming to all the requirements
shall be accompanied by a Certificate in accordance with clause 13 of IS 7285 (Part 2).

5. LEVELS OF CONTROL - The tests as indicated in column 1 of Table 1 and the levels of
control in column 3 of Table 1, shall be carried out on the whole production of the factory which is
covered by this plan and appropriate records maintained in accordance with paragraph 2 above.

6. HEAT TREATMENT - The heat treatment of cylinders shall be done as per clause 5.5 of
IS 7285 (Part 2). The cylinders shall be punched with serial number before heat treatment to
maintain traceability throughout the manufacturing process.

6.1 Adequate care shall be taken to ensure the consistency of heat treatment cycle. The deviation of
temperature shall be within the specified temperature range. In case the temperature goes outside
the specified limits, furnace shall be stopped and all such cylinders shall be segregated.
Heat treatment shall be resumed only after attaining the requisite temperature and the furnace
temperature is maintained between the specified limits. The complete records of heat treatment
cycle and interruptions of cycle shall be maintained.

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7. INSPECTION AND TESTING/ RE-TESTS

7.1 In order to ensure that the cylinders are in compliance with IS 7285 (Part 2), they shall be
subjected to Inspection and Testing in accordance with clause 8 of IS 7285 (Part 2).

7.2 In the event of failure of cylinders in meeting the requirements, procedure in accordance with
clause 7.10.1 of IS 7285 (Part 2) shall be followed for retesting/re-heat treatment.

8. REJECTIONS – Disposal of non-conforming product shall be done in such a way so as to

ensure that there is no violation of provisions of BIS Act, 2016.

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 PM/ IS 7285 (Part 2)/ 1/ Jan 2019

TABLE 1

(1) (2) (3)

Test Details Test equipment Levels of Control
Cl. Requirement Test Methods requirement No. of Frequency Remarks
Clause/ R: required (or) Sample
Reference S: Sub-contracting
permitted
5. MATERIAL
5 Steel 5.1 to IS 7285 (Part 2) S One Each cast/ heat The cylinder manufacturer shall obtain
5.3 certificates of cast (heat) analysis of
steel.
5.4 IS 7285 (Part 2) --- Each Batch
5.5
6.7, Material for neck ring 6.7 IS 7285 (Part 2) S Two Each No further testing is necessary if the
6.8.2 and foot ring 6.8.2 consignment consignment is received with Test
(As per design/ drawing) Certificate.

6 DESIGN
6.6 Neck Design 6.6.1 IS 7285 (Part 2) R Each cylinder
6.6.2
Valve Fittings 6.6.3 IS 7285(Part 2) R Each cylinder
---
6.7 Foot Ring 6.7 IS 7285 (Part 2) R Each cylinder

6.8 Neck Ring and Cap 6.8 IS 7285 (Part 2) R Each cylinder
7 MANUFACTURE
7.1 General 7.1 IS 7285(Part 2) R Each cylinder
---
7.2 Wall thickness 7.2 IS 7285 (Part 2) R Each cylinder

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 PM/ IS 7285 (Part 2)/ 1/ Jan 2019

7.3 Surface defects 7.3 IS 7285 (Part 2) R Each cylinder

Annex-A ---
7.4 Ultrasonic 7.4 IS 7285 (Part 2) R Each cylinder The ultrasonic testing shall be certified
Examination Annex-B by the cylinder manufacturer. Every
cylinder which has passed the ultrasonic
testing shall be stamp marked with the
symbol “UT”
7.5 Out - of - roundness 7.5 IS 7285 (Part 2) R Each cylinder

7.6 Mean Diameter 7.6 IS 7285 (Part 2) R Each cylinder

7.7 Straightness 7.7 IS 7285 (Part 2) R Each cylinder

7.8 Verticality 7.8 IS 7285 (Part 2) R Each cylinder ---

7.9 Stability 7.9 IS 7285 (Part 2) R Each cylinder

7.11 Water Capacity 7.11 IS 7285 (Part 2) R Each cylinder

9 TYPE APPROVAL PROCEDURE

9.2.2.b.1 Hydraulic Bursting 10.5 IS 7285 (Part 2) R As per clause 9.2.2.(b) of Each new design of cylinder as well as
Test IS 7285 (Part 2) any change in design as per the details
given in clause 9.1 of IS 7285 (Part 2)
9.2.3 Pressure Cycling Test 9.2.3 IS 7285 (Part 2) R shall be subjected to prototype testing.
If the results are satisfactory type
9.2.4 Base Check 9.2.4 IS 7285 (Part 2) R approval certificate shall be issued as
per clause 9.3 of IS 7285 (Part 2).
9.2.5 Sulphide Stress 9.2.5 IS 7285 (Part 2) R As per clause 9.2.5 and
Cracking Resistance 9.2.5.1 9.2.5.1 of IS 7285 (Part 2)
Test

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 PM/ IS 7285 (Part 2)/ 1/ Jan 2019

10 BATCH TESTS

Tensile Test 10.2 IS 7285 (Part 2) R As per clause 10.1.3 of IS Each new design of cylinder as well as
7285 (Part 2) any change in design as per the details
Impact Test 10.3 IS 7285 (Part 2) R given in clause 9.1 of IS 7285 (Part 2)
10.1.3 shall be subjected to batch tests for
Bend Test 10.4 IS 7285 (Part 2) R prototype testing.
Hydraulic Bursting 10.5 IS 7285 (Part 2) R
Test
10.6 Pressure Cycling Test 10.6 IS 7285 (Part 2) R One cylinder

11 TEST ON EVERY CYLINDER

11.2 Hydrostatic Stretch 11.2 IS 7285 (Part 2) R Each cylinder

Test
11.3 Hardness Test 11.3 IS 7285 (Part 2) R Each cylinder

11.4 Leakage Test 11.4 IS 7285 (Part 2) R Each cylinder

(Pneumatic)
11.5 Water Capacity Check 7.11 IS 7285 (Part 2) R Each cylinder ---
12 Colour Identification 12 IS 7285 (Part 2) R Each cylinder

14 Cylinder Marking 14 IS 7285 (Part 1) -- Each cylinder

17 Preparation for 17 IS 7285 (Part 1) -- Each cylinder

despatch

Note-1: Sub-contracting is permitted to a laboratory recognized by the Bureau or Government laboratories empanelled by the Bureau.

Note-2: The control unit and levels of control given in column 3 are obligatory in nature to which the licensee shall comply with.

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 PM/ IS 7285 (Part 2)/ 1/ Jan 2019

ANNEX C

Possible Tests in a day

i) Wall thickness and other dimensions/requirements as per approved drawing

ii) Surface defects
iii) Ultrasonic examination
iv) Hardness Test
v) Tensile Test
vi) Bend test
vii) Impact Test
viii) Water Capacity
ix) Hydrostatic Stretch Test
x) Leakage Test
xi) Hydraulic Bursting Test

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 PM/ IS 7285 (Part 2)/ 1/ Jan 2019

ANNEX D

Scope of the Licence

Licence is granted to use Standard Mark as per IS 7285 (Part 2 ):2017 with the following scope:

Name of the product REFILLABLE SEAMLESS STEEL GAS CYLINDERS -

QUENCHED AND TEMPERED STEEL CYLINDERS WITH
TENSILE STRENGTH LESS THAN 1 100 MPa (112 kgf/mm²)

Type Material
Water Capacity (litre)
Diameter (mm)
Wall thickness (mm)
Working Pressure (bar or kgf/cm2)
Test Pressure (bar or kgf/cm2)
Bottom Profile
Gas application

Any Other Aspect PESO approved drawing number and approval number
required as per Standard

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