LPG VALVE MANUFACTURING
[CODE 3747]
Valves are a type of mechanical device that are implemented to regulate flow, pressure, or both, within a system. They an integral aspect of any piping system that requires a fair amount of control. The primary functions of a conventional valve comprise flow control in the form of rate of flow and the direction of flow. Valves are thus used to prevent back flow, and relieving pressure. The various valve types, designs, and models can be functional in specific industrial, commercial, and residential applications.
LPG valves may need to be designed especially for maintaining high pressure within the cylinder and to let out the gas at a rate specified and within regulatory permission. These valves are also designed to withstand the possible damage they may take during transportation. An additional cap is often screwed over the valve in order to further reduce the likelihood of gas leakage when the cylinder is not in use.
The gas cylinder valve is the primary safety mechanism on a gas cylinder and shall not be tampered with. It is a device used to contain the contents of the cylinder that is under pressure. Cylinder valves are fitted with pressure relief valves of different types (depending on the cylinder) to protect against catastrophic failure of the cylinder valve.
Cylinder valves open in an anticlockwise direction and close in a clockwise direction. Valves shall never be opened without a regulator attached. Always open cylinder valves slowly
There two basic types of LP Gas cylinder valves for vapour service, namely, self-closing, clip-on valves and hand wheel operated valves. They can come with or without pressure relief valves depending on local regulations.
1. Self-Closing, Clip-on Valve
These are typically used for domestic cylinders where low cost and fit for service valves are required. Common types in the market are compact, bayonet, or snap on (snap tight) valves. They can be fitted with excess flow limiters and/or anti-dirt tubes (also called education tubes). Because these valves are open-topped, plastic dust caps are recommended to be fitted during storage and transportation to prevent entry of foreign matter.
Performance Requirements
i. The valve shall be of the self-closing type, closed by gas pressure in the cylinder assisted by a small stainless steel spring.
ii. The valve shall be completely gas-tight and shall have no regulating function that can restrict high filling rates.
iii. The 13kg and 50kg cylinder valves shall be with a safety relief valve. The 3kg and 6kg cylinder shall be fitted with camping valves.
iv. If it is with a safety relief valve, then the safety relief valve shall be of pop-action type and shall have a set pressure of 2.55 MPa.
v. The safety relief valve shall open to allow blow-off should the cylinder pressure under extreme conditions reach 2.94MPa.
vi. The capacity of the safety relief valve when fully open shall be 5.0 cubic meters of air per minute.
vii. The spindle shall be able to move freely.
2. Hand Wheel Operated Valve
These valves are used both with domestic and commercial cylinders and are designed for different applications i.e. liquid fill, liquid service and vapour service. The outlet connection of hand wheel operated valves can come in different forms e.g. CGA 510 (or F.Pol), CGA 555 (or M.Pol), ACME, NPT, etc. When both vapour and liquid connections are on the same valve, they must be designed differently for clear distinction. Liquid service valves are fitted with a tube and an excess flow limiter. Hand wheel operated valves can accidentally be opened and it is recommended to fit a gas tight plug after filling while the cylinder is in transport or storage.
COST ESTIMATION
Plant Capacity 4000 Pieces/Day
Land & Building (4050 sq.mt.) Rs. 68 Lac
Plant & Machinery Rs. 48 Lac
Working Capital for 1 Months Rs. 65 Lac
Total Capital Investment Rs. 1.95 Cr
Rate of Return 60%
Break Even Point 53%
INTRODUCTION
1. SELF-CLOSING, CLIP-ON VALVE
PERFORMANCE REQUIREMENTS
2. HAND WHEEL OPERATED VALVE
PARTS OF LPG VALVE
B.I.S. SPECIFICATION
PROCESS FLOW CHART
MANUFACTURING PROCESS
THE MAIN STEPS ARE GIVEN BELOW:
1. PROCUREMENT OF RAW MATERIAL
2. TESTING OF RAW MATERIAL
3. CUTTING THE BRASS BILLET FOR REQUIRED SIZE FOR BALL
AND VALE BODY
4. HEATING THE BRASS BILLET UP TO FORGING TEMP.
5. CLOSE-DIE FORGING PROCESS
CLOSED DIE FORGING PROCESS OPERATIONS
UPSETTING
VIEW
ADVANTAGES OF CLOSED DIE FORGING:
HIGH STRENGTH
LEAK RESISTANCE
CLOSE TOLERANCES
LOW OVERALL COST
6. TRIMMING AND CLIPPING
7. DIP FINISHING
8. MACHINING
9. QUALITY CONTROL
ACTIVITIES
INSPECTION OF PACKING AND DESPATCH.
INSPECTION OF IN-COMING MATERIALS
IN- PROCESS INSPECTION
FINAL INSPECTION
CONTROL OF MEASURING, INSPECTION TOOLS AND TEST EQUIPMENTS
10. TESTING
(A) TESTING OF BRASS MATERIAL
1. TENSILE STRENGTH AND ELONGATION
2. IMPACT STRENGTH
3. STRESS CORROSION TEST
4. HYDROSTATIC TESTS
(B) TESTING OF NON-METALIC MATERIAL
(C) TESTING OF SPRING
TEST METHOD
2. RUST PROOFNESS TEST (NITRIC ACID IMMERSION TEST)
(D) TESTING OF ASSEMBLE VALVE
1. DIMENSION TEST
1. PNEUMATIC TEST
2. TIGHTNESS OF JOINT PACKING (IN VALVE OUTLET) AND VALVE SPINDLE.
4. TIGHTNESS OF VALVE SPINDLE AND VALVE HOUSING
5. TIGHTNESS OF JOINT PACKING AND HOUSING
6. CYCLE TEST
7. OPERATION TEST
PROCEDURE
8. IMPACT TEST
PROCEDURE
9. EXTERNAL LEAKAGE TEST
10. SEAT LEAKAGE TEST
11. ENDURANCE TEST
12. HYDROSTATIC STRENGTH TEST
11. MARKING
MARKET SURVEY
LPG IN INDIA
PRADHAN MANTRI UJJWALA YOJANA
PAHAL
GIVE IT UP
INDIA LPG MARKET (2012-2026): INCREASING CONSUMPTION OF LPG TO PRODUCE VARIOUS CHEMICAL COMPONENTS - RESEARCH AND MARKETS
MAIN INDUSTRY
INDIAN LPG SCENARIO
ANALYSIS OF IMPORT OF LPG VALVE
TOTAL VALUE & VOLUME OF IMPORTS IN INDIA
ANALYSIS OF EXPORT OF LPG VALVE
TOTAL VALUE & VOLUME OF EXPORTS IN INDIA
MANFACTURERS/SUPPLIERS OF LPG CYLINDER VALVE
CHINA SUPPLIERS FOR COMPLETE PLANT
SUPPLIERS OF PLANT AND MACHINERIES
SUPPLIERS OF BRASS BILLET CUTTING MACHINE
SUPPLIERS OF CLOSE DIE HOT FORGING MACHINE
SUPPLIERS OF FORGING DIES
SUPPLIERS OF INDUCTION HEAING FURNACE
SUPPLIERS OF CNC LATHE MACHINE
SUPPLIERS OF CNC MACHINING CENTRE
SUPPLIERS OF SHOT BLASTING MACHINE
SUPPLIERS OF METAL TESTING MACHINE
SUPPLIERS OF HARDNESS TESTING MACHINE
SUPPLIERS OF NDT INSPECTION EQUIPMENT
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF BRASS BILLET
SUPPLIERS OF NITRILE RUBBER SEAL
SUPPLIERS OF PICKLING ACIDS
SUPPLIERS OF VALVE SPRING
SUPPLIERS OF PICKLING ACIDS
PACKAGING MATERIALS
PLANT LAYOUT
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
