PM/ IS 7142/1/ May 2019

PRODUCT MANUAL FOR

WELDED LOW CARBON STEEL CYLINDERS FOR
LOW PRESSURE LIQUEFIABLE GASES
NOT EXCEEDING 5 LITRE WATER CAPACITY
ACCORDING to IS 7142:1995
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 7142:1995
Welded low carbon steel cylinders for low pressure
Title : liquefiable gases not exceeding 5 litre water
capacity

No. of Amendments : 1
2. Sampling Guidelines:
a) Raw material : Clause 4 of IS 7142
Each variety of Cylinders shall be tested for
b) Grouping guidelines : GoL/CSoL. [Please see clause 16 and 17 of IS 7142
also]

c) Sample Size : As per clause 16 and 17 of IS 7142

3. List of Test Equipment : Please refer ANNEX – A.

Scheme of Inspection
4. : 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 7142/1/ May 2019

ANNEX A

List of Test Equipment

Major test equipment required to test as per the Indian Standard

Sl. Tests used in with Clause Test Equipment

No. Reference
1 Agreed Finish Thickness, Profile a) Dial Vernier caliper,
regularity, circularity, offset at the b) Ultrasonic mini thickness gauge,
joint, Straightness (Clause 8) c) Goose Neck Gauge, Micrometer,
d) Profile Gauge,
e) Circularity gauge,
f) Straightness gauge fixture
g) Height Gauge

2 Valves and Bungs (Clause 9 and 10) a) Thread Gauges,

b) Torque wrench

3 Heat treatment (Clause 11) a) Pyrometer,

b) Temperature Controller,
c) Temperature recorder and
d) Temperature indicator

4 Water capacity (Clause 13 ) a) Weighing Balance

5 Proof Test (Clause 14 ) b) Hydrostatic Test Bench (non-Jacket

6 Hydrostatic Stretch Test and method)
Bursting Test (Clause 16 ) c) Hydrostatic Test Bench

7 Pneumatic Leakage Test (Clause 15) a) Pneumatic Test facility,

b) Pressure Gauge

8 Acceptance Test (Clause 17) a) Universal Testing Machine

b) Marker and Punch
c) Scale
d) Vernier

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

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 PM/ IS 7142/1/ May 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 Pressure Gauges - At least once in a month
1.1.3 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 shall be made available to the inspecting authority
and purchaser of cylinder. Copies of test certificates shall be forwarded to the statutory
authority, purchaser of the cylinder and the inspecting authority.
3. LABELLING AND MARKING - As per the requirements of IS 7142:1995.
4. BATCH - For the purpose of this scheme, Cylinders of identical type and design constructed
from steel of similar analysis made by the same steel manufacturer and heat treated during one
continuous production run in the same manner and under similar conditions 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 21 of IS 7142.

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 the cylinders shall be done as per clause 11
of IS 7142. The cylinders shall be punched with serial number before heat treatment to maintain
traceability throughout 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.
7. 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 7142/1/ May 2019

TABLE 1

(1) (2) (3)

Test Details Test Equipment Levels of Control
Requirement

Cl. Requirement Test Methods R: required (or) No. of Sample Frequency Remarks
S: Sub
Clause Reference contracting
permitted
4 MATERIAL

4.1 Steel for cylinder 4.1 IS 7142 S One Each cast/ The cylinder manufacturer shall
heat obtain certificates of cast (heat)
analysis of steel.

4.2 Bung/Valve pad 4.2 IS 7142 S Two Each No further testing is required, if
Consignment accompanied with test certificate or
4.3 Backing Strip 4.3 IS 7142 S Two ISI marked.
Material

4.4 Foot-rings 4.4 IS 7142 S Two

7 Welding 7.1 to 7.8 IS 7142 R Each Cylinder _ _

8 Manufacture 8 IS 7142 R Each Cylinder _ _

9 Valves and Valves 9 IS 7142 R Each Valve and _ _

Pad Valve Pad

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 PM/ IS 7142/1/ May 2019

10 Test of Handle or 10.1 IS 7142 R One cylinder from each lot of _

other suitable 403 cylinders or less (consisting
arrangement of two consecutive batches)

Foot- ring 10.2 IS 7142 R Each Foot- ring _ _

Bung 10.3 IS 7142 R Each Bung

11 Heat Treatment 11 IS 7142 R Each Cylinder _ _

12 Inspection 12.1.3 IS 7142 R Each Cylinder/Component _

13 Checking of Water 13 IS 7142 R Each Cylinder _ _

Capacity
14 Proof Test 14 IS 7142 R

15 Pneumatic Leakage 15 IS 7142 R

Test

16 Hydrostatic Stretch 16.1 IS 7142 R As per clause 16.1 of IS 7142 _

Test
Bursting Test 16.2 IS 7142 R As per clause 16.2 of IS 7142 _

17 Acceptance Tests 17 IS 7142 R As per clause 17 of IS 7142 _

18 Marking 18 IS 7142 R Each cylinder _

19 Colour Identification 19 IS 7142 R Each Cylinder _

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 PM/ IS 7142/1/ May 2019

20 Preparation of 20 IS 7142 R 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.
Note-3: The Stage Inspection for manufacturing of cylinders shall be as per Annex I.
Note-4: The Test Certificate for cylinders shall be as per Annex II.

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 PM/ IS 7142/1/ May 2019

ANNEX-I

STAGE INSPECTION FOR MANUFACTURING OF LPG CYLINDERS

1. Material:
a) Check physical and chemical properties of each cast/heat.

b) Check dimensions and surface defects (visual).

2. Manufacturing of Components:

Body Bung Foot Ring Back strips

(Upper half and lower (wherever
half) provided)

Check pressing for Check blanks, forging for Check for Check for
thickness and surface cracks and other surface dimensions and dimensions
defects such as cracks defects. other defects. and surface
and laminations. defects.
Random check of After manufacturing check Random check for
height to maintain dimensions and threading by data stamped.
water capacity. gauges.

3. Assembly:

a) Check top and bottom halves for defects and traces of oil.
b) Inspect welding defects of body, bungs and foot ring.
c) Inspect tack welding of back strip, if provided.
d) Check for permanent volumetric expansion.
e) Check for defects/leakage after hydraulic test and pneumatic test.
f) Select cylinders for acceptance, burst test and hydrostatic stretch test.
g) Check bung threads, leakage between valve and bung and leakage of the cylinder
(pneumatically).
h) Check all cylinders for water capacity.
i) Check for internal cleaning and drying.
j) Check for weight of each empty cylinder with valve.
k) Inspect fitting of cap on cylinders and details stamped on the cylinder.
l) Check for coating thickness after metallizing and painting.
m) Final visual inspection after painting.

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 PM/ IS 7142/1/ May 2019

ANNEX-II

GAS CYLINDER CERTIFICATE

Certificate No……………………
Date……………………………..

Manufacturer:
Purchaser: ……………………………
Order No.: ……………………………
Batch No.: ……………………………
Cylinder Description ………….litre water capacity. Two piece welded Cylinder working pressure
16.9 kgf. /cm2 at 65 °C

This is to certify that the cylinders manufactured, inspected and tested as mentioned below during the
period from …………… to …………………………….. at M/s
………………………………………………………………………………………… meet the
requirements of IS 7142: 1995, Drawing No --------------------------------

The Cylinders have been fitted with self-closing type of valves as per ----------

METHOD OF MANUFACTURE

1. Welding Process:
2. Method of Support:
3. Heat Treatment:
INSPECTION : TESTS:

4. Bung & Bung Welding :OK 12. Hydrostatic stretch test at ………….kgf/cm2
5. Foot ring welding & Marking :OK 13. Hydraulic Pressure test at ……….. kgf/cm2
6. Internal examination before closing-in-operation: OK 14. Leakage test at …………..kgf/cm2 (using air)
7. i) Circumferential & Longitudinal welding :OK 15. Acceptance test: Report No……….dt………
ii) Serial No. Stamping :OK (Annex-IIIA)
8. Check for: 16. Burst test:
i. Liquid Penetration Examination of Bung welding: OK a. Cylinder No……………………….
ii. Bung threads :OK b. Burst Pressure…………………. kgf/cm2
iii. Cap Threads :OK c. Nominal hoop stress……………kgf/cm2
9. Leakage with valve fitted; No leakage to cylinder :ok d. Cylinder bursted without fragmentation : Yes
10. Valve Caps :OK
11. Finishing & Painting :OK

QUANTITY PASSED: CYLINDERS PASSED ----------NOS

Tested/Rejected:………………….. Cylinder Nos (Annex III B)

Cast No. of Steel ……………………… Cast No. of Steel ………………………

i. Tensile………………. kgf/mm2 i. Tensile………………. kgf/mm2
ii. Yield………………… kgf/mm2 ii. Yield………………… kgf/mm2
iii. Elongation…………………...% iii. Elongation…………………...%

Steel used IS………………..Gr……..... Steel used IS………………..Gr…….....

C% Si% Mn% S% P% C% Si% Mn% S% P%

Representative of Licensee Inspecting Officer (BIS)

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 PM/ IS 7142/1/ May 2019

ANNEX IIIA

ACCEPTANCE TESTS

Certificate No……………………
Date……………………………..

Tested Cylinder Nos: …………………

Batch No.: …………………………… Cylinder Nos ……………………..

Tested at.: …………………………

Particulars Longitudinal with Circumferential Longitudinal

Weld (W) parent metal (C) parent metal (L)
Width (mm)
Thickness (mm)
Cross-sectional area
(mm2)
Gauge Length (mm)
Yield load (kgf)
Yield Stress
(kgf/mm2)
Tensile load (kgf)
Tensile Strength
(kgf/mm2)
Final Length (mm)
Elongation (mm)
% Elongation
Position of Fracture

Bend Test: Macro and Micro Examination:

a) Root --- a) Neck ------

b) Face ---- b) Body ----

Minimum Thickness Test … mm

Representative of Licensee Inspecting Officer (BIS)

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 PM/ IS 7142/1/ May 2019

ANNEX III B

DETAILS OF REJECTION/TESTING

Certificate No……………………
Date……………………………..

Batch No.: ……………………………

Cylinder No. : Tested/Rejected Cylinders

Acceptance Test Burst Test Burnout Cracks

Welding Offset Lamination Localized thinning Others

Total tested/rejected cylinders………………………….Nos. as detailed above

Representative of Licensee Inspecting

Officer (BIS)

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 PM/ IS 7142/1/May 2019

ANNEX C

Possible Tests in a day

i) Acceptance Tests
ii) Burst Test
iii) Hydrostatic Stretch Test
iv) Pneumatic Leakage Test
v) Wall thickness and other dimensions/requirements as per approved drawing
vi) Water Capacity

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 PM/ IS 7142/1/May 2019

ANNEX D

Scope of the Licence

Licence is granted to use Standard Mark as per IS 7142:1995 with the following scope:

Name of the product WELDED LOW CARBON STEEL CYLINDERS FOR

LOW PRESSURE LIQUEFIABLE GASES
NOT EXCEEDING 5 LITRE WATER CAPACITY

Type Water Capacity (litre)

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

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