Detailed Project Report (DPR) on cng cylinder testing plant

CNG CYLINDER TESTING PLANT

[CODE NO.3795]  

CNG is the compressed form of Natural Gas,which is mainly composed of methane [CH4]), which is less than 1% of the volume it occupies at standard atmospheric pressure so that large volume of gas can be stored in CNG cylinder. Final filling pressure of CNG in the vehicle cylinder is limited to 200 bar.

CNG is successfully used as a fuel in our transport system from Decades, more popularly termed as "Green Fuel". CNG is widely used in Auto rickshaws, Cars & Buses. For use in Automobiles as fuel, it is compressed to a pressure of 200-250 bar to enhance the vehicle on-boardstoragecapacity. CNG or Compressed Natural Gas is a fossil fuel substitute for petrol, diesel, or LPG. CNG is more environmentally clean alternative to those fuels, and it is much safer than other fuels in the event of a spill.

CNG cylinders are strong and light weight and undergo stringent cyclic testing to assess fatigue strength, usage life and to ensure safety and reliability under extreme climate conditions. A wide range of CNG cylinders are designed and designed and manufactured to comply with national and international standard (Reinforcement.com, 2007). High-quality stainless steel CNG cylinders and cascade of cylinders are available for different capacities and various kinds of vehicles, like three-wheelers, cars, buses and delivery vehicles as shown in Figure 24  a and b.

The storage tanks for compressed natural gas (CNG cylinders) must be strong, lightweight, and resistant to impact and temperature. Cylinders can be divided into the following three groups, depending on the materials used in their manufacture:

• Metallic

• Mental-composite (metal liner strengthened by polymer composite material; and

• Composite (polymer liner strengthened by polymer composite material).

Gas cylinders are the heavier portion of alternative fuel systems which adds more weight to vehicle unlades weight. In search of innovative materials for gas cylinders, composite material has been the front runner in reducing weight of the vehicle, thereby reducing fuel consumption significantly. This report describes the various types of composite cylinders, their design & test requirements, merits and demerits of each type of composite cylinder.

This report explains various new and effective technologies in Cylinders that are available internationally, its regulatory requirements and usage. In India Type 1, 2, 3 have been successfully used in Indian Automotive Industry Chief Controller of Explosives (CCOE), Nagpur is the approval authority for CNG Cylinders in India.

This unique report will also provide you with valuable information, insights about vehicles with Type 4 Cylinders, history of composite cylinders and detailed analysis of all the four types of CNG Cylinders

Current status of adoption of composite cylinder technology in India and worldwide, such as number of composite cylinder manufacturers in world, level of introduction of composite cylinders in different types of vehicles and incidents happened due to composite cylinders are also described in this report. Based on review of composite cylinder technology, it is concluded that all-composite cylinder technology (i.e., Type-4 cylinders) is the best solution for light weighting of automotive heavy commercial vehicles such as buses without compromising on safety.

COST ESTIMATION

Plant Capacity                                  100 Nos/Day

Land & Building                                  Rented

Plant & Machinery                             Rs. 86 Lac

Working Capital for 2 Months         Rs. 22 Lac

Total Capital Investment                  Rs. 1.42 Cr

Rate of Return                                   22%

Break Even Point                              75%

• INTRODUCTION
• TYPE OF CNG CYLINDERS
• CYLINDER TYPES INCLUDE:
• TABLE 1: TYPE OF CNG CYLINDERS
• 1. TYPE 1 CYLINDER – ALL METAL.
• 2. TYPE 2 CNG CYLINDERS - HOOP WRAPPED COMPOSITE.
• 3. TYPE 3 CNG CYLINDERS – FULLY WRAPPED COMPOSITE WITH METAL LINERS.
• 4. TYPE 4 CNG CYLINDERS - FULLY WRAPPED COMPOSITE WITH NON-METALLIC LINERS.
• B.I.S. SPECIFICATION
• PROCESS FLOW CHART
• TESTING PROCESS OF CNG CYLINDER
• TESTING OF CNG CYLINDERS
• TESTS FOR CNG CYLINDERS
• NO OF TEST SPECIMENS
• REQUIREMENTS:
• A) HIGH TEMPERATURE CREEP TEST
• B) ACCELERATED STRESS RUPTURE TEST
• C) IMPACT DAMAGE TEST (DROP TEST)
• REQUIREMENTS:
• D) PERMEATION TEST
• E) FLAW TOLERANCE TEST
• F) ACID ENVIRONMENT TEST
• DIFFERENT CHEMICALS CAN BE USED:
• G) AMBIENT TEMPERATURE PRESSURE CYCLE TEST
• REQUIREMENTS:
• H) BURST TEST
• I) BON-FIRE TEST
• REQUIREMENTS:
• J) INTERNAL/EXTERNAL CORROSION
• K) CHEMICAL AND UV RESISTANCE
• I) FATIGUE IN CYCLING
• M) OVERPRESSURE DURING FILLING OR DUE TO TEMPERATURE CHANGES
• N) IMPACT AND ABRASION
• HYDROSTATIC STRETCH TESTING OF COMPRESSED GAS CYLINDERS
• 1. WATER JACKET METHOD
• 2. NON-JACKET METHOD
• FACILITIES REQUIRED FOR CYLINDER TESTING STATIONS
• 1. MANAGEMENT:
• 2. EQUIPMENT:
• GLOBAL MARKET POSITION
• GLOBAL CNG GAS CYLINDER INDUSTRY -BACKGROUND AND CHARACTERISTICS
• CNG CYLINDER STANDARDS IN DIFFERENT COUNTRIES:
• CNG CYLINDER REGULATIONS IN DIFFERENT COUNTRIES
• GLOBAL CNG CYLINDER MARKET
• TABLE: CNG CYLINDER MARKET
• COMPANIES MANUFACTURING TYPE 4 CYLINDERS:
• PENETRATION OF TYPE-4 COMPOSITE CYLINDERS IN AUTO INDUSTRY
• FOLLOWING ARE LIST OF SOME BUS MANUFACTURERS WHO ARE USING TYPE-IV GAS CYLINDERS:
• TABLE: TYPE 4 CYLINDER MARKET POSITION ON CITY BUSES IN EUROPE
• TABLE: TYPE 4 CYLINDER MARKET POSITION ON CITY BUSES IN NORTH AMERICA
• FOLLOWING ARE SOME OF THE BRANDS THAT ARE USING TYPE-4 CYLINDERS:
• FIGURE: BRANDS USING TYPE 4 COMPOSITE CYLINDERS
• GLOBAL CNG GAS CYLINDER MARKET
• NATURAL GAS VEHICLES DATA FOR IANGV:
• TABLE: POPULATION OF NGV’S AND REFUELING STATIONS
• FIGURE: NATURAL GAS VEHICLE COUNT BY REGION (1991-2010)
• FIGURE: ACTUAL AND PROJECTED VOLUMES OF NGV’S
• FIGURE: AVERAGE ANNUAL GROWTH RATE OF NGV’S BY REGION
• FIGURE: NGV GROWTH PROJECTION TILL 2014
• FIGURE: ESTIMATED PRODUCTION OF COMPOSITE REINFORCED CNG CYLINDERS
• PLANT LAYOUT
• PRESENT MANUFACTURERS AND SUPPLIERS
• SUPPLIERS OF CNG CYLINDER TESTING PLANT

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)