FJM Cylinders Pvt. Ltd.

1. Submitted T o Dr. R.K. Garg Dr. Pardeep Kumar Presentation on 6 weeks summer internship Submitted B y Sahil Garg 12001004055 ME Final Yr.

2. FJM Cylinders Pvt. Ltd . Bawal , Rewari Global partnerships

3. About Company The major duo of automotive parts manufacturing in India, JBM Group and N.K. Minda Group joined hands for a joint venture with Faber Industry of Italy to manufacture high pressure gas cylinders . Faber are the world's premier name in the field of CNG cylinders manufacturing with a comprehensive range of cutting - end technology available around the world. The Promoters in India have a very sizeable Engineering and R & D force and believe in constant innovation of product . The plant is having a high degree of automation with processes and layout based on Faber technology. JBM Group is a focused, dynamic and progressive organization that provides customers with value added products, services and innovative solutions. The Group has a diversified portfolio to serve in the field of automotive, engineering & design services, renewable energy and education sectors and has an infrastructure of 35 manufacturing plants, 4 engineering & design centres across 18 locations globally. Company‘ theme Tag I – Integrity S – Safety Q - Quality

4. CNG Composition – Component T y pi c a l An a l y sis ( mole %) Meth a ne 95 Etha n e 3.2 P rop a ne 0.2 I s o - B uta n e 0.03 No r mal B uta n e 0.03 H e x a n e s plus 0.01 Nitrog e n 1.0 C o 2 0.5 O 2 0.02 H 2 tr ace s

5. Advantages CNG does not contain any lead, thereby eliminating fouling of spark plugs. CNG-powered vehicles have lower maintenance costs than other hydrocarbon- fuel-powered vehicles. CNG fuel systems are sealed, preventing fuel losses from spills or evaporation. Increased life of lubricating oils, as CNG does not contaminate and dilute the crankcase oil. Being a gaseous fuel, CNG mixes easily and evenly in air. CNG is less likely to ignite on hot surfaces, since it has a high auto-ignition temperature (540 °C), and a narrow range (5–15 percent) of flammability. Less pollution and more efficiency : CNG emits significantly fewer pollutants ( e.g., carbon dioxide (CO2 ), unburned hydrocarbons(UHC), carbon monoxide (CO), nitrogen oxides (NOx), sulfur oxides ( SOx ) and PM (particulate matter) than petrol . For example, an engine running on petrol for 100 km emits 22 kilograms of CO2, while covering the same distance on CNG emits only 16.3 kilograms of CO2. Carbon monoxide emissions are reduced even further. Due to lower carbon dioxide and nitrogen oxides emissions, switching to CNG can help mitigate greenhouse gas emissions. The ability of CNG to reduce greenhouse gas emissions over the entire fuel lifecycle will depend on the source of the natural gas and the fuel it is replacing. CNG-powered vehicles are considered to be safer than gasoline-powered vehicles.

6. Process Layout

7. Tube Cutting The process of cutting the required cylinder tube lengths from the chunks of 150- 200 meters. C y l i nd e r Si z e W a ter C a p ac i ty Cut t ube len g th L + 3 / - S qu a r e n e ss ‗’S’ m a x . 232 × 5 TP C O 50 1540 2.4 267 × 5.7 TP C O 30 837 2.7 267 × 5.7 TE N A R I S 35 937 2.7 316 × 6.7 TE N A R I S 60 1097 3.2 316 × 6.7 TPCO 60 1110 3.2 316 × 6.7 TPCO 65 1180 3.2 356 × 7.6 TPCO 65 995 3.6 406 × 8.6 TPCO 180 1857 4.1

8. S L To check the lengths of the tube within the range – Mostly OK To check the Squareness value of the tubes with setsquare – Always OK Parameters – Ø Cutting Feed Scale (rev/min.) = 2 - 4.5 ( used = 3) Ø Cutting Fluid – AWS 68 ( cooldage ) Ø Cutting coil – Bimetallic Bandsaw coil sized 5300×41×1.3 Ø Vice Clamping Pressure = 35 – 45 Kg/cm2 Ø Blade Tension = 40 – 45 Kg/cm2 TPCO = High-quality Cylinder Steel Pipes and seamless steel pipe Drawing

9. Induction Heating and Bottom Spinning Induction Heat Furnace (Heating Torch Burner)   Induction heating is the process of heating an electrically conducting object (usually a metal) by electromagnetic induction, through heat generated in the object by eddy currents generated through copper tubes of Heat Exchanger. Before spinning, tube area that had to undergo seamless bending, its temperature is raised to recrystallization tempr so that the process of spinning can be carried out fastly and precisely. Also intense care is undertaken in taking the tube from heat furnace to spinning section so that time taken is limited to 2 – 3 seconds. Voltage – Measured Value PV – 11870C Supply Value SV – 13000C (while working with 316×6.7)

10. Bottom Spinning It is the process in which the red hot tube section is grinded and bended continuously along with the water cooling, tip removal, Metal feeding to the high speed rotating tube. It is accompanied in stages i.e. a . Cooling and Bending for nearly 70% of total time b . Tip removal for 10% of time c . Surface finish by grinder ( burner off ) for 15% of time d . Material filling for 5% of time Parameters – Grinder material = D2/(H11) Burners – O2 (2.5 bar) + LPG (0.5 bar) Spinning Temperature – 10500C Cutting Torch – DA (acetylene + O2) Cooling water hose inlet pressure = 3 – 4 bar Ejector air pressure = 5 – 6 bar Clamping Pressure = 40 – 50 bar Material Filling ≈ 15mm

11. Drawing L1 L R T To check For E316×6.7×60 L +/- 3 = 1002 L1 = Max.125 T = 10.05 R = 255

12. Induction Heating and Neck Spinning The grinder used in the neck spinning is two stage grinder coalesced with the resin bonded material with the bending roll somewhat roughly finished than the neck forming roll thereby getting somewhat extra portion behind the neck for the accuracy purpose.

13. To check For 316×6.7×60 L e n g th L 1 m i n. 35 N ec k r a dius r 10 N ec k r a dius R 165 D 3 m a x . 45 D 2 ma x . 19 D 1 m i n. 42 Tot a l C y l i nd e r L e n g th 965 - 975

14. Heat Treatment Hardening - The use of this treatment will result in an improvement of the mechanical properties, as well as an increase in the level of hardness, producing a tougher, more durable item. Quenching - Alloys may be air cooled, or cooled by quenching in oil, water, or another liquid, depending upon the amount of alloying elements in the material and final mechanical properties to be achieved. Hardened materials are tempered to improve their dimensional stability and toughness. Tempering - Tempering is the process of reheating the steel at a relatively low temperature leading to precipitation and spheroidization of the carbides present in the microstructure. Tempering is done to develop the required combination of hardness, strength and toughness or to relieve the brittleness of fully hardened steels . Polymer Concentration – Checked by Refractometer Temperature measure - Pyrometer   Polymer used – S205. It is added in water to avoid cracking of cylinder when immersed in water after hardening. It gets burned when comes in contact of cylinders. So, its concentration needs to be checked time to time.

15. Pressure Cyclic Test Two random cylinders, after the Heat Treatment of the batch are selected for this test and pressure cycled between, a upper pressure of 334 bar and a lower pressure of 30 bar for 12,000 cycles. The rate of pressurization should not exceed 15 cycles per minute. Shell temperature of the cylinder during the test is measured and recorded and it should not exceed 50°C. Cylinder should not leak up to the completion of 12,000 pressure cycles.

16. Setup B r. 8 B r. 6 B r. 4 B r. 3     Qu e n c hi n g B r. 6 B r. 5 B r. 2 B r. 1 B r. 7 B r. 5 B r. 2 B r.1 B r . 8 B r. 7 B r. 4 B r. 3 Z o n e 3 Z o n e 2 Z o n e 1 Z o n e 2 Z o n e 1 Tempering Hardening To check for E316×6.7×60   H a rd e ni n g F u r n a c e T e m p r ( + 0 / - 10 ) o C     Z o n e 1 890 Z o n e 2 895     P o l y m e r Con ce n t r a t i on ( % ) 9 – 11   Qu e n c h a nt T e m p r ( o C ) 50   T e mpe r i n g F u rna c e T e m p r ( + /- 5 ) o C     Z o n e 1 580 Z o n e 2 580 Z o n e 3 580     Qu e n c hi n g Time ( s ec .) 120     C y c le Time 200

17. Hardness Test After tempering, we check for the hardness of the cylinder to ensure for the desired mechanical properties. Hardness is a characteristic of a material, not a fundamental physical property. It is defined as the resistance to indentation, and it is determined by measuring the permanent depth of the indentation. More simply put, when using a fixed force (load) and a given indenter, the smaller the indentation, the harder the material . BHN is designated by the most commonly used test standards (ASTM E10-14nd ISO 6506–1:2005) as HBW (H from hardness, B from brinell and W from the material of the indenter, tungsten (wolfram) carbide). In former standards HB or HBS were used to refer to measurements made with steel indenters.

18. HBW is calculated in both standards using the SI units as Where :   F = applied force (N) D = diameter of indenter (mm) d = diameter of indentation (mm)

19. Specifications –   Ø Ball material – SS Ø Ball diameter – 5mm, 10mm Ø Load – 750Kg, 3000Kg To check for E316×6.7×60 Tempered Cylinder Hardness Range 280 – 330 HBW Indentation diameter ( d) 1.815 – 1.680 mm

20. Neck Machining and Inspection To check for C406×8.6 Plug Gauges 25.4 mm 14 full form 25.4 mm 14 effective form To check min. Ø at small end To check min. Ø at large end W a ter C a p ac i t y 180 C y l i nd e r L e n g th 1652 - 1664 Ma c hined N ec k diam e t e r ( D) 42 - 44 Th rea d S i z e I S 3224 Taper Thread Plug Gauge Plain Plug Gauge

21. Water Capacity Measurement and Hydrostatic Stretch Test Hydrostatic Stretch test means subjecting the cylinder to a hydrostatic pressure equal to the test pressure of the cylinder and recording the permanent stretch undergone by the cylinder. Hydrostatic Testing is a non-destructive test procedure used to check cylinders for leaks, structural flaws, durability, and corrosion. It is used to check a cylinder‘s structural integrity. Check Sheet C y l i nd e r Si z e Ø316 × 6.7 Nominal W a ter C a p ac i t y 6 L A cce p t a ble W a ter C a p ac it y R a n g e 58.5 – 61.5 L T e st P r e ssure 334 b a r T e st pr e ssure hold t i m e 30 s ec . Tot a l Volu m e tric E x p a nsion ( m l ) At ac tual P e rm a n e nt e x p a nsion Not more than 10% of t o tal e x p a nsion L e a k a ge No l ea k a g e , vis i ble bulge or d e fo r m a t i on R e du c t i on in P r e ssure No re du c t i on in pr e ss u re wh e n c y l i nd e r is und e r t e st S y stem P r e ssure 150 b a r min. Air Pr e ssure 6 b a r min.

22. Air Leakage Test Air Leakage Test – This is carried out to check for the leakage (if any) in the cylinder surface through gas filling. This test is carried by dipping the cylinders in the water bath (6 at a time). Before this the necks are tight fitted with the gas pipe valves. Then the supply of pressurized nitrogen is started at 200 bar. Cylinders attain weight and starts submerging in the water. Then manual detection of air bubbles or fuss noise is noticed then there is a leakage in the cylinder. After attaining the level of 350 bar the gas supply is turned off. Wait till the pressure drops to zero. Then relieve the pipe fittings and the cylinders are moved to the steam cleaning section one by one.

23. Steam Cleaning Test After the air leakage test, the cylinders are delivered to the steam cleaning section. In this section there is rig available of two cylinders at a time . Firstly , the cylinders are held tight from the neck portion in the base plate ( attached to the platform) via pneumatic operated holders. Then the platform is lifted up to the straight vertical position so that the mouth of the cylinder is bottom facing The pipe with the valve attachment is fastened into the neck. Then the steam supply at test pressure of 155 Kg/cm2 is turned ON. There is provided some clearance provided between neck and attachment so that steam and water can discharge out after condensing. This testing goes for nearly 15 minutes when the discharge starts coming out in the form of steam only. Then the steam supply is turned off and attachment is removed. Also a stick is used to remove the chips (if any) formed during the neck threading process in the vertical position only by revolving the stick (slight bend at the end). After this the platform is brought to the initial position, cylinders are released from holders and moved back via conveyor.

24. Air Drying Test This is basically the drying of the cylinder in the atmospheric air. As the cylinder have passed through steam testing the temperature of the cylinder goes up and with the heat rejection the cylinder is kept for nearly 12-14 minutes for drying in the storage section from where it is transferred via conveyor to the internal shot blasting . Precautions – Proper drying is necessary otherwise during the shot blasting the shots will stuck to the internal surface and will ultimately deter the quality. Gloves are compulsory while handling the steam cleaning test as the temperatures of the cylinder rises to 110-150oC.

25. Internal and External Shot Blasting Internal Shot Blasting – This process consists of improving the surface finish of the internal surfaces with the help of blasting the internal surface with the minute steel balls with the help of high speed rotating nozzle with two mouth opening. The nozzle is carried in the steel lance. The complete chamber is closed during the process . External Shot Blasting – In this set up the multiple nozzles are incorporated in the horizontal chamber. The specifications remain the same except the ball size which is 1mm at this time. It is done just after internal shot blasting but on different setup. A rubber cap is tightened to the neck to prevent the damaging of the threads. Before this it is ensured that there are no steel balls left in the cylinder after the internal shot blasting via check through bulb rod

26. C omponents need to be checked periodically during the blasting are – a) Dust Collector – In this tank the steel balls after use are dumped in so that they can be re used. And also the fresh steel balls are fed in this tank only for the regular supply to the machine b) Leather pipe – The left out long chips are carried by this pipe from the cylinder. So it needs check time to time for the proper working c) Suction Pipe – The desired air pressure is supplied via suction pipe from air tank to the nozzle. So, before starting the power supply of the nozzle, this air pressure build up is turned ON.     S te e l balls     Ø0.8 mm S 330     S te e l L a n c e     Ø16.5 × 3 × 4000     Air p r e ssu r e   5.5 - 6.5 K g /c m 2     T a r g e t     16 c y l / h r . Time Requir e d 1m i n. – L o a di n g 4m i n. – P ro c e ss 1m i n. - Unlo a ding

27. Data Stamping The data stamping machine is universal i.e all three direction stamping is performed X – Stamping Slide Y – Lateral Slide Z – Angular Slide X Y Z

28. T esting Material Test Tensile Test Bend Test Impact Test SSCR Test The sample for test(s) a,b and c above are selected by BIS and PESO Faridabad during the manufacture of Prototype and the tests are conducted in house in the presence of BIS and PESO. The sample for test ‘d’ above are selected by BIS and PESO and the sealed sample is send to third party lab approved by BIS for testing. The test results are directly send to BIS by the lab.

29. Stamp A A U B 0 4 6 F J M C M / L 9 9 9 6 6 2 9 0 6 / 2 0 1 5 I S 1 5 4 9 T P 3 3 4 B A R A A U B 0 4 6 T W 6 0 . 6 K G W C 6 0 . 0 L W P 2 0 0 B A R O N B C N G DO NOT USE AFTER 06/2035 Meanings – AAUB – Batch code 046 – Cylinder No. FJM – Company name CM/L 9996629 – company manufacturing license no . 06/2015 – month and year of manufacture IS 15490 – Indian Standards TP – Test Pressure TW – Tear weight WC – Water Capacity ONB – On Board

30. Primer Painting P rimer Co a t i ng Thi c k n e s s 40 µ m ( min.) P a in t ing D e f ec ts Th e re should not be a n y ov e r f low, dust, o ra n g e p ee l a nd bl i ste r s Ov e n T e mp e r a tu r e 80 C + / - 10 C B a ki n g Time 20 – 25 m i ns. B ot t om Gun a ir p r e ssure 6 K g /cm2 (min.) R ec ipro ca t o r a ir p r e ssure 1.5 – 2.5 K g /cm2 (min.) Time 20 – 30 s ec . Thinn e r 20% of to t a l vo l ume P rimer a nd H a rd e n e r mixing r a t i o 4:1

31. Finish Painting P rimer + P a int Co a t i ng T hickn e ss 80 µ m ( min.) P a in t ing D e f ec ts Th e re should not be a n y ov e r f low, dust, o ra n g e p ee l and bliste r s Ov e n T e mp e r a tu r e 80 C + / - 10 C B a ki n g Time 40 – 45 m i ns. B ot t om Gun a ir p r e ssure 6 K g /cm 2 (min.) R ec ipro ca t o r a ir p r e ssure 1.5 – 2.5 K g /cm 2 (min.) Time 20 – 30 s ec . Thinn e r 20% of to t a l vo l ume P a int a nd H a rd e n e r mi x i ng r a t i o 3:1 S a lt S p r a y T e st Th e re should not be a n y r e d rust in 500 hrs.

32. Valve Assembly Procedure –   Affix the cylinder neck to the base plate. Make sure that the glue tape be winded on the valve accurately so that there will not be any problem in tightening the valve to the cylinder Scan the QR code of the valve for the system entry. Start only after getting green signal from the setup. Firstly take the valve, place it to the neck slightly, put the face plate over the valve then hold the gun with hand, place it onto the face plate and hold the button. Release the button when the setup indicates red light. T hen place the gun apart and the valve is checked for torque via Torque Wrench manually for the perfection. Precaution – The acceptable torque is within +/- 10 ranges. If it is over tightened then valve is damaged and if it is somewhat less tightened then there is danger of leakage. So, a skilled operator is assigned this task usually. C y l i nd e r Si z e Ø316 × 6.7 mm W a ter C a p ac i t y 60 L To r que 270 Nm

33. Frame Assembly The measuring of the Tare weight of cylinder after de-gassing. Then lifting it up and putting on the fixture for frame assembling. Using pneumatic adjuster cylinder is adjusted as per the markings on the fixture. Then frame is tightened on the cylinder. It consists of three straps and one bottom The bolts are tightened to the strap to strap and the strap to frame. It is divided into two parts – Initial bolt tightening will take place after two hours of de-gassing Final bolt tightening and checking will take place after two hours of initial bolt tightening The finally the stickers of CNG and Precaution are pasted on the cylinder.

34. PDI