Rylinder Refurbishment Plant

KAYA is engaged in the project design, manufacturing and installation of turnkey plants for below listed activities according to all relevant international standards, particularly EN and DOT standards.

Refurbishment (Repairing) of the LPG cylinders (with cold repair and hot repair facility)

Scrapping of the LPG cylinders

Requalification of the LPG cylinders

Repairing and Requalification of the LPG cylinder valves

Testing of LPG cylinder

Testing of LPG Cylinder .Refurbishment (Repairing) of LPG Cylinders:

The physical condition of the LPG cylinders can be impaired by abuse, the use of inappropriate distribution equipment and continuous use and exposure to elements. Regular maintenance, repair and re-qualification are required to ensure that they remain appropriate for service. This can be achieved by inspecting and then separating defective and damaged cylinders for proper action when they are returned to the filling facility for re-filling.

Steel cylinders should be inspected for the following defects and damage:

• Partial or worn markings/finish
• Leaking valves, damaged valves, valves with missing consumer seals, etc.
• Serious dents, bulges and gouges
• Corrosion pits, lines and general corrosion
• Fire damage and scorching
• Cylinders due for periodic inspection and testing

Details of Scrapping of Cylinders:

Cylinders that are identified as being outside the rejection limits or beyond the economic cost of repair compared to the price of new cylinders should be processed for scrap. These cylinders should be gas freed before being scrapped and made totally unsuitable for further service.

Cold Repair:

Repairs of minor defects, such as bent guard rings or foot rings, can be carried out in a designated part of the refurbishment plant. Bent guard rings and foot rings can often be straightened rather than replaced.  Straightening is a much cheaper operation than cutting and welding because it avoids hot work and should always be considered the first option.  Machines are available which use mandrills and hydraulic pressure to re-form the shape.  Great care should be taken to avoid cracking.

Details of Hot Repair:

Cylinders requiring major repair, involving welding and/or de-denting, must be gas freed, tested and certified gas free before being processed.  Essential aspects are:

• Removal guard or/and foot rings
• Fitting new guard or/and foot rings
• Dent removal

Details of Requalification of Cylinders:

Cylinders must be pressure tested at periodic intervals and re-qualified for a further period of service.  The periodic examination/testing must be performed according to national legal requirements, the requirements of the code to which the cylinder was manufactured or a local industry standard, whichever is the most stringent.

• Ex-proof Area Machines and Equipment
  • LPG Degassing Unit
  • Valve Removing Unit
  • Cylinder Inside Washing Machine (Inline – Outline)
  • Residual Water Suction and Cleaning Unit (Inline – Outline)
  • Residual Gas Burning Unit (Inline)
  • Cylinder Internal Inspection Unit (Inline)
• LPG Cylinder Scrapping Machines
• Hydraulic Scrapping Presses
• Guard Ring Straightening Unit
• Foot Ring Straightening Unit
• Guard & Foot Ring Removing Machine
• Grinding Unit
• Guard & Foot Ring Welding Machine
• Blowing and Redenting Machine
• LPG Cylinder Cold Repairing Machines and Equipment
• LPG Cylinder Hot Repairing Machines and Equipment
• Shot Blasting Machine
• Automatic Metallization Line
• Automatic Electrostatic Powder Painting Line
• Automatic Second Color Wet Painting Line
• Automatic Combined Metallization & Electrostatic Powder Painting & Wet Painting Line
• Automatic Tare Weighing Scale & Ink Jet Printing Unit (Inline)
• Tare Weight Manual Punching Unit
• Flange Cleaning Unit (Inline)
• Valve Screwing Unit (Inline)
• Air Leakage Test Unit (Inline)
• Vacuuming Unit (Inline)
• Serigraphy Machine
• Multi-Color Pad Printing Machine
• Heat Treatment Unit
• All types of floor and overhead conveyors
• Lifting equipment, pressurized air & cooling water & air ventilation etc. systems
• Hydrostatic Test Unit (Inline – Outline)
• Surface Preparation and Coating Line
• LPG Cylinder Test and Finishing Line
• LPG Cylinder Valve Repairing and Testing Machines and Equipment
• LPG Cylinder Transferring Systems
• Production Auxiliary Equipment
• Water Treatment System for LPG Cylinder Washing Water

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