Project Report_CNG Cylinders

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Market Analysis for Export of CNG Pressure Cylinders to Uzbekistan

By

Kedar Rajendra Gosavi

A PROJECT REPORT

Submitted to

BHARATI VIDYAPEETH UNIVERSITY

In partial fulfilment of the requirements

For the award of the POST GRADUATE DIPLOMA

In

INTERNATIONAL BUSINESS MANAGEMENT

Bharati Vidyapeeth University - Amplify DITM,

April – 2011

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Bonafide Certificate

Certified that this project report titled Market Analysis for Export of CNG Pressure

Cylinders to Uzbekistan is the bonafide work of Mr. Kedar Rajendra Gosavi who carried

out the research under my supervision. Certified further, that to the best of my knowledge

the work reported herein does not form part of any other project report or dissertation on

the basis of which a degree or award was conferred on an earlier occasion on this or any

other candidate.

(Certificate to be signed by the Project Guide)

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Abstract

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Acknowledgement

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Table of Contents

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List of Tables

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List of Figures

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Chapter 1

Introduction

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Pressure Vessels

A pressure vessel is a closed container designed to hold gases or liquids at a pressure substantially different from the ambient pressure.

The design, manufacture, and operation are regulated by engineering authorities backed up by laws. For these reasons, the definition of a pressure vessel varies from country to country, but involves parameters such as maximum safe operating pressure and temperature.

Pressure vessels are used in a variety of applications in both industry and the private sector. They appear in these sectors as industrial compressed air receivers and domestic hot water storage tanks.

No matter what shape it takes, the minimum mass of a pressure vessel scales with the pressure and volume it contains and is inversely proportional to the strength to weight ratio of the construction material (minimum mass decreases as strength increases)

Compressed Natural Gas – CNG

Compressed natural gas (CNG) is a fossil fuel substitute for gasoline (petrol), diesel, or propane/LPG. Although its combustion does produce greenhouse gases, it is a more environmentally clean alternative to those fuels, and it is much safer than other fuels in the event of a spill, natural gas is lighter than air, and disperses quickly when released. CNG may also be mixed with biogas, which doesn't increase the concentration of carbon in the atmosphere.

CNG is made by compressing natural gas (which is mainly composed of methane [CH4]), to less than 1% of the volume it occupies at standard atmospheric pressure. It is stored and distributed in hard containers at a pressure of 2900–3600 psi, usually in cylindrical or spherical shapes.

Types & Variety of CNG Cylinders

Type - 1 All Metal CylindersThis type of cylinders is cheap but is heavy in weight, but are the most sold type of

cylinders all over the world.SteelSteels shall be aluminium - and/or silicon freeAluminiumAluminium alloys may be used to produce cylinders provided that they meet all requirements of this International Standard and have maximum lead and bismuth contents not exceeding 0,003 %.

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Design RequirementsTest pressureThe minimum test pressure used in manufacture shall be 300 bar (1.5 times working pressure).Burst pressureThe minimum actual burst pressure shall be not less than 450 bar.Stress analysisThe stresses in the cylinder shall be calculated for 200 bar, test pressure and design burst pressure. The calculations shall use suitable analysis to establish stress distributions to justify the minimum design wall thicknesses.Maximum defect sizeThe maximum defect size at any location in the metal cylinder such that the cylinder shall meet pressure cycling and LBB requirements shall be specified.OpeningsOpenings are permitted in heads only. The centre line of openings shall coincide with the longitudinal axis of the cylinder.Fire protectionThe cylinder design shall be protected with pressure relief devices. The cylinder, its materials, pressure relief devices (PRD) and any added insulation or protective material shall be designed collectively to ensure adequate safety during fire conditions. Pressure relief devices shall be approved to a standard acceptable to the Inspector in the country of use.AttachmentsWhen a neck ring, foot ring or an attachment for support is provided, it shall be of material compatible with that of the cylinder and shall be securely attached by a method other than welding, brazing or soldering.

Construction and WorkmanshipEnd closureEach cylinder shall be examined for thickness and surface finish before end forming operations are carried out. The base ends of aluminium cylinders shall not be sealed by a forming process.Heat treatmentAfter end forming the cylinders shall be heat treated to the hardness range specified for the design.Neck threadsThreads shall be clean cut, even, without surface discontinuities, to gauge and comply with International StandardsExterior environmental protectionThe exterior of cylinders shall meet the requirements of the acid environment test.Exterior protection may be provided by using any of the following:a) A surface finish giving adequate protection (e.g. metal sprayed on to aluminium, anodizing); orb) A protective coating (e.g. organic coating, paint).c) A covering impervious to the chemicals.

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Any coatings applied to cylinders shall be such that the application process does not adversely affect the mechanical properties of the cylinder. The coating shall be designed to facilitate subsequent in-service inspection.

Type - 2 Hoop-Wrapped CylindersDuring pressurization, this type of cylinder design exhibits behaviour in which the

displacements of the composite overwrap and the metal liner are linearly superimposed. Due to different techniques of manufacture, the International Standard does not give a definite method for design.

The design shall ensure a “leakage-before-break” failure mode under feasible degradation of pressure parts during normal service. If leakage of the metal liner occurs, it shall be only by the growth of a fatigue crack.

MaterialsSteelSteels shall be aluminium- and/or silicon-killed and produced to predominantly fine grain practice.AluminiumAluminium alloys may be used to produce cylinders provided they meet all requirements of the International Standard and have maximum lead and bismuth contents not exceeding 0,003 %.

Composite MaterialsResinsThe material for impregnation may be thermosetting or thermoplastic resins.Examples of suitable matrix materials are epoxy, modified epoxy, polyester and vinylester thermosetting plastics, and polyethylene and polyamide thermoplastic material.FibresStructural reinforcing filament material types shall be glass fibre, aramid fibre or carbon fibre. If carbon fibre reinforcement is used the design shall incorporate means to prevent galvanic corrosion of the metallic components of the cylinder.

Design RequirementsTest pressureThe minimum test pressure used in manufacture shall be 300 bar (1.5 times working pressure).Burst pressures and fibre stress ratiosThe metal liner shall have a minimum actual burst pressure of 260 bar.The composite over-wrap shall be designed for high reliability under sustained loading and cyclic loading. This reliability shall be achieved by meeting or exceeding the composite reinforcement stress ratio values.Stress ratio is defined as the stress in the fibre at the specified minimum burst pressure divided by the stress in the fibre at working pressure.The burst ratio is defined as the actual burst pressure of the cylinder divided by the working pressure.The stress ratio calculations shall include

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a) An analysis method with capability for non-linear materialsb) Correct modelling of the elastic-plastic stress-strain curve for a known liner material;c) Correct modelling of the mechanical properties of composite materials;d) Calculations at auto frottage pressure, zero pressure after auto frottage, working pressure, and minimum burst pressure;e) Account for the pre stresses from winding tension;f) The minimum burst pressure, chosen such that the calculated stress at minimum burst pressure divided by the calculated stress at working pressure meets the stress ratio requirements for the fibre used;g) Consideration of the load share between the different fibres based on the different elastic module of the fibres when analysing cylinders with hybrid reinforcement.Verification of the stress ratios may also be performed using strain gauges.Stress analysisThe stresses in the composite and in the liner after pre stress shall be calculated for 0 bar, 200 bar, test pressure and design burst pressure. The calculations shall use suitable analysis techniques taking into account non-linear material behaviour of the liner when establishing stress distributions.For designs using auto-frottage to provide pre stress, the limits within which the auto-frettage pressure shall fall shall be calculated and specified. For designs using controlled tension winding to provide pre stress, the temperature at which it is performed, the tension required in each layer of composite and the consequent pre stress in the liner shall be calculated.Maximum defect sizeThe maximum defect size at any location in the metal liner such that the cylinder meet pressure cycling and LBB requirements shall be specified.OpeningsOpenings are permitted in heads only. The centre line of openings shall coincide with the longitudinal axis of the cylinder.Fire protectionThe cylinder design shall be protected with pressure relief devices. The cylinder, its materials, pressure relief devices and any added insulation or protective material shall be designed collectively to ensure adequate safety during fire conditions.Pressure relief devices shall be approved to a standard acceptable to the Inspector in the country of use.

Construction & WorkmanshipGeneralThe composite cylinder shall be manufactured from a liner over-wrapped with continuous filament windings. Fibre winding operations shall be computer or mechanically controlled. The fibres shall be applied under controlled tension during winding. After winding is complete, thermosetting resins shall be cured by heating, using a predetermined and controlled time-temperature profile.Neck threadsThreads shall be clean cut, even, without surface discontinuities, to gauge and comply with International Standards.

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Over-wrapFibre windingThe cylinders shall be manufactured by a fibre winding technique. During winding the significant variables shall be monitored within specified tolerances and documented in a winding record. These variables can include but are not limited to:a) Fibre type including sizing;b) Manner of impregnation;c) Winding tension;d) Winding speed;e) Number of roving;f) Band width;g) Type of resin and composition;h) Temperature of the resin;i) Temperature of the liner;j) Winding angle.Curing of thermosetting resinsIf a thermosetting resin is used, the resin shall be cured after filament winding. During the curing, the curing cycle (i.e. the time-temperature history) shall be documented.The maximum curing time and temperature for cylinders with aluminium alloy liners shall be below the time and temperature which adversely affect metal properties.Auto-frettageAuto-frettage, if used, shall be carried out before the hydrostatic pressure test.Exterior environmental protectionThe exterior of cylinders shall meet the requirements of the acid environment test.Exterior protection may be provided by using any of the following:a) A surface finish giving adequate protection (e.g. metal sprayed on to aluminium, anodizing); orb) The use of a suitable fibre and matrix material (e.g. carbon fibre in resin); orc) A protective coating (e.g. organic coating, paint);d) A covering impervious to the chemicals.Any coatings applied to cylinders shall be such that the application process does not adversely affect the mechanical properties of the cylinder. The coating shall be designed to facilitate subsequent in-service inspection.

Minimum actual burst values and stress ratios for Type - 2 cylinders

Fibre Type Stress Ratio Burst Pressure (bar)Glass 2,75 500 (a)

Aramid 2,35 470Carbon 2,35 470

(a) Min actual burst pressure , in addition confirm that the min stress ratio requirement are also met

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Type - 3 Fully-Wrapped CylindersDuring pressurization, this type of cylinder exhibits behaviour in which the

displacements of the composite overwrap and the liner are superimposed. Due to different techniques of manufacture, this International Standard does not give a definite method for design.

The design shall ensure a “leakage-before-break” failure mode under feasible degradation of pressure parts during normal service. If leakage of the metal liner occurs, it shall be only by the growth of a fatigue crack.

MaterialsSteelSteels shall be aluminium- and/or silicon-killed and produced to predominantly fine grain. AluminiumAluminium alloys may be used to produce cylinders provided they meet all requirements of the International Standard and have maximum lead and bismuth contents not exceeding 0,003 %.

Composite MaterialsResinsThe material for impregnation may be thermosetting or thermoplastic resins. Examples of suitable matrix materials are epoxy, modified epoxy, polyester and vinylester thermosetting plastics, and polyethylene and polyamide thermoplastic material.FibresStructural reinforcing filament material types shall be glass fibre, aramid fibre or carbon fibre. If carbon fibre reinforcement is used the design shall incorporate means to prevent galvanic corrosion of metallic components of the cylinder.

Design RequirementsTest pressureThe minimum test pressure used in manufacture shall be 300 bar (1.5 times working pressure).Burst pressures and fibre stress ratiosThe composite over-wrap shall be designed for high reliability under sustained loading and cyclic loading. This reliability shall be achieved by meeting or exceeding the composite reinforcement stress ratio values. Stress ratio is defined as the stress in the fibre at the specified minimum burst pressure divided by the stress in the fibre at working pressure.The burst ratio is defined as the actual burst pressure of the cylinder divided by the working pressure.The stress ratio calculations shall include:a) An analysis method with capability for non-linear materials (special purpose computer program or finite element analysis program);b) Correct modelling of the elastic-plastic stress-strain curve for a known liner material;c) Correct modelling of the mechanical properties of the composite;d) Calculations at autofrettage pressure, zero pressure after autofrettage, working pressure and minimum burst pressure;

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e) Account for the pre stresses from winding tension;f) The minimum burst pressure, chosen such that the calculated stress at minimum burst pressure divided by the calculated stress at working pressure meets the stress ratio requirements for the fibre used;g) Consideration of the load share between the different fibres based on the different elastic module of the fibres when analysing cylinders with hybrid reinforcement.Verification of the stress ratios may also be performed using strain gauges.Stress analysisA stress analysis shall be performed to justify the minimum design wall thicknesses. It shall include the determination of the stresses in liners and fibres of composite designs.The stresses in the tangential and longitudinal direction of the cylinder in the composite and in the liner after pre stress shall be calculated for 0 bar, 200 bar, test pressure and design burst pressure. The calculations shall use suitable analysis taking into account non-linear material behaviour of the liner when establishing stress distributions.Maximum defect sizeThe maximum defect size at any location in the metal liner such that the cylinder meet pressure cycling and LBB requirements shall be specified.OpeningsOpenings are permitted in heads only. The centre line of openings shall coincide with the longitudinal axis of the cylinder.Fire protectionThe cylinder design shall be protected with pressure relief devices. The cylinder, its materials, pressure relief devices and any added insulation or protective material shall be designed collectively to ensure adequate safetyPressure relief devices shall be approved to a standard acceptable to the Inspector in the country of use.

Construction & WorkmanshipGeneralThe composite cylinder shall be manufactured from a liner over-wrapped with continuous filament windings. Fibre winding operations shall be computer or mechanically controlled. The fibres shall be applied under controlled tension during winding. After winding is complete, thermosetting resins shall be cured by heating, using a predetermined and controlled time-temperature profile.LinerThe compressive stress in the liner at zero pressure and 15 °C shall not cause the liner to buckle or crease.Neck threadsThreads shall be clean cut, even, without surface discontinuities, to gauge and comply with International Standards acceptable to the Inspector.Over-wrapFibre windingThe cylinders shall be manufactured by a fibre winding technique. During winding the significant variables shall be monitored within specified tolerances and documented in a winding record. These variables can include but are not limited to:a) Fibre type including sizing;

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b) Manner of impregnation;c) Winding tension;d) Winding speed;e) Number of roving;f) Band width;g) Type of resin and composition;h) Temperature of the resin;i) Temperature of the liner;j) Winding angle.Curing of thermosetting resinsIf a thermosetting resin is used, the resin shall be cured after filament winding. During curing, the curing cycle (i.e. the time-temperature history) shall be documented.The maximum curing time and temperature for cylinders with aluminium alloy liners shall be below the time and temperature which adversely affect metal properties.Auto-frettageAuto-frettage, if used, shall be carried out before the hydrostatic pressure test.Exterior environmental protectionThe exterior of cylinders shall meet the requirements of the acid environment test. Exterior protection may be provided by using any of the following:a) A surface finish giving adequate protection (e.g. metal sprayed on to aluminium, anodizing); orb) The use of a suitable fibre and matrix material (e.g. carbon fibre in resin); orc) A protective coating (e.g. organic coating, paint);d) A covering impervious to the chemicals.Any coatings applied to cylinders shall be such that the application process does not adversely affect the mechanical properties of the cylinder. The coating shall be designed to facilitate subsequent in-service inspection.


Fibre Type Stress Ratio Burst Pressure (bar)Glass 3,65 700 (a)


(a) Min actual burst pressure , in addition confirm that the min stress ratio requirement are also met

Type -4 All-Composite CylindersMaterialsGeneral requirementsThe design shall ensure that incompatible materials are not in contact.ResinsThe material for impregnation may be thermosetting or thermoplastic resins. Examples of suitable matrix materials are epoxy, modified epoxy, polyester and vinylester thermosetting plastics, and polyethylene and polyamide thermoplastic material.

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FibresStructural reinforcing filament material types shall be glass fibre, aramid fibre or carbon fibre. If carbon fibre reinforcement is used the design shall incorporate a means of preventing galvanic corrosion of metallic components of the cylinder.Plastic linersThe polymeric material shall be compatible with the service conditions.Metal end bossesThe metal end bosses connected to the non-metallic liner shall be of a material compatible with the service conditions

Design RequirementsTest pressureThe minimum test pressure used in manufacture shall be 300 bar (1.5 times working pressure).Burst pressures and fibre stress ratiosThe composite over-wrap shall be designed for high reliability under sustained loading and cyclic loading. This reliability shall be achieved by meeting or exceeding the composite reinforcement stress ratio values. Stress ratio is defined as the stress in the fibre at the specified minimum burst pressure divided by the stress in the fibre at working pressure.The burst ratio is defined as the actual burst pressure of the cylinder divided by the working pressure.For type -4 designs, the stress ratio is equal to the burst ratio.Verification of the stress ratios may also be performed using strain gauges.Stress analysisA stress analysis shall be performed to justify the minimum design wall thicknesses. It shall include the determination of the stresses in liners and fibres of composite designs.The stresses in the tangential and longitudinal direction of the cylinder in the composite and in the liner shall be calculated. The pressures used for these calculations shall be 0 bar, 200 bar, test pressure and design burst pressure. The calculations shall use suitable analysis techniques to establish stress distribution throughout the cylinder.OpeningsOpenings are permitted in the end bosses only. The centre line of openings shall coincide with the longitudinal axis of the cylinder.Fire protectionThe cylinder design shall be protected with pressure relief devices. The cylinder, its materials, pressure relief devices and any added insulation or protective material shall be designed collectively to ensure adequate safety during fire conditionsPressure relief devices shall be approved to a standard acceptable to the Inspector in the country of use.

Construction & WorkmanshipGeneralThe composite cylinder shall be manufactured from a liner over-wrapped with continuous filament windings. The fibres shall be applied under controlled tension during winding.

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After winding is complete, thermosetting resins shall be cured by heating, using a predetermined and controlled time-temperature profile.Neck threadsThreads shall be clean cut, even, without surface discontinuities, to gauge and comply with International StandardsCuring of thermosetting resinsThe curing temperature for thermosetting resins shall be at least 10 °C below the softening temperature of the plastic liner.Exterior environmental protectionThe exterior of cylinders shall meet the requirements of the acid environment. Exterior protection may be provided by using any of the following:a) A surface finish giving adequate protection (e.g. metal sprayed on to aluminium, anodizing);b) The use of a suitable fibre and matrix material (e.g. carbon fibre in resin);c) A protective coating (e.g. organic coating, paint);d) A covering impervious to the chemicals.Any coatings applied to cylinders shall be such that the application process does not adversely affect the mechanical properties of the cylinder. The coating shall be designed to facilitate subsequent in-service inspection.


Fibre Type Stress Ratio Burst Pressure (bar)Glass 3,65 730


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Chapter 2

Domestic Production & Consumption of CNG Cylinders

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Domestic Production Areas

The production of CNG cylinders is carried out across all the main cities in the nation. But the key cities where the production is carried out at a larger scale are as listed below:

- Aurangabad, Maharashtra- Gandhidham, Gujarat- Tarapur, Maharashtra- Visakhapatnam, Andhra Pradesh

Types produced in India

Generally the Type – 1 & 2 are produced in India, but Type – 3 cylinders can also be produced if there is a demand by the importer.

Quality Parameters for Production

The parameters for the production of CNG Cylinders for domestic as well as for the exports are laid down by the International Organisation for Standardisation (ISO) in the article ISO-11439 titled as “Gas cylinders — High-pressure cylinders for the on-board storage of natural gas as a fuel for automotive vehicles.” The first edition of this article was published on 15ht of September 2000.

This article lays down the specific requirements for manufacturing of all the four types of cylinders & the specific set of tests that all the cylinders have to go through in order to be fitted in the vehicle.

Testes performed on CNG CylindersPerformance Testing

Qualification tests required by standards to ensure tanks and components will perform safely when subject to automotive service conditions.

However, automotive OEM can perform additional tests to ensure the durability of the fuel storage system.

Hydraulic Pressure Cycle TestingThis is done using water instead of gas at the same time is easier to perform the

test. Failure of this test means leak in the cylinder & not the rupturing of the cylinder.

Low Temperature-Pressure TestingAfter the hydraulic pressure test is performed, the cylinder is chilled to -40F. Then

the tank is heated to 149F. This is followed by more pressure cycle testing.

Drop Impact TestingThe CNG cylinder is dropped from a certain height so that the impact of falling

form a considerable height is measured & accordingly changes are made in the composition of material of the cylinder in order to bare the impact.

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Drop Test during Pressure CycleSimilar to the drop impact test, in this test also the cylinder is dropped down from

a considerable height but in this case the cylinder is dropped with some pressure filled in it, 7 then the necessary changes are made to meet the demand.

Bonfire TestingThis test is performed in order to make sure that the gas will vent before the

cylinder is ruptured, when it is exposed to fire.

Environmental Exposure TestIn this the cylinder is exposed to road salt bath of various concentrations. At the

same time in the solution white pads are stick to it containing battery acid, fertilizer solution, gasoline, etc.

While exposed to solutions cylinders are also pressure cycled with fluid to stimulate filling & emptying.

CNG Permeation TestingThis test is carried on the Type-4 cylinder, which is inserted in sealed chamber to

measure the amount of CNG permeates through plastic liner over time.

Apart from this test the gunfire testing, vibration of vehicle fuel system testing & hydraulic crush testing is also performed in order to make the cylinder not to burst in any condition possible.

MarkingsOn each cylinder the manufacturer has to provide clear permanent markings not

less than 6 mm high. Marking shall be made either by labels incorporated into resin coatings, labels attached by adhesive, low stress stamps used on the thickened ends of type CNG-1 and CNG-2 designs, or any combination of the above. Adhesive labels and their application shall be in accordance with ISO 7225 or an equivalent standard acceptable to the Inspector in the country of imports. Multiple labels are allowed and should be located such that they are not obscured by mounting brackets.

A sample of the marking on the cylinderCNG ONLYDO NO USE AFTER 3/2009Manufacturer/Identification number200 bar/15 °CISO 11439:2000 CNG-2 (registration no.)“Use only manufacturer-approved PRD”Manufacture date 08/98

Following is a flow chart of the process involved in manufacturing of the CNG cylinders

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CNG Cylinder Manufacturing Process

Domestic Consumption (Size of Local Market)

Growth in the cylinder industry is largely led by growth in demand for CNG cylinders. Demand for cylinders has grown to a CAGR of 19% over FY06-FY09E. Traditionally, high-pressure seamless cylinders catered to the medical, industrial, fire fighting and beverages segment. The advent of CNG as an eco-friendly automotive fuel has opened new avenues for the industry. At the same time, use of cylinders for other purposes like medical, industrial and defence purposes is also growing at a steady pace.

Sector-wise growth in CNG Cylinder Demands (in Lakhs)

Sector FY-04 FY-05 FY-06 FY-07 FY-08 FY-09 Growth RateAuto 1.37 1.73 2.18 2.75 3.47 4.37 26%Medical 0.55 0.61 0.67 0.73 0.81 0.89 10%Industrial 0.55 0.61 0.67 0.73 0.81 0.89 10%Defence 0.27 0.30 0.33 0.37 0.4 0.44 10%Total 2.75 3.25 3.85 4.58 5.48 6.58 19%

The market for CNG and LPG cylinders, used for automotive purposes, is growing at a fast clip. The need for a clean fuel and rising costs of petrol and diesel are leading to a shift towards cleaner and less-expensive fuels. Taking a leaf out of Delhi’s experience, other cities too are expected to shift to alternate fuels soon. The Supreme Court has

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mandated that 28 cities should shift to CNG. This could open up newer markets and lead to higher growth rates compared to other user segments. The CNG automotive cylinder segment is the fastest growing market in India.

Number of CNG-fuelled vehicles

FY-04 FY-05 FY-06 FY-07 FY-08 FY-09 CAGRBuses 400 4,231 8,874 10,199 10,480 10,941 93.82%Auto 14,000 35,678 49,810 59,027 62,048 65,335 36.08%RTV 250 2,165 4,934 5,267 5,469 5,634 86.46%

Others 11,700 15,166 15,505 16,098 16,249 24,573 16%Total 26,350 57,240 79,123 90,591 94,246 106,483 32.22%

Project Report_CNG Cylinders

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