1. Equipment qualification and operation qualification requirements
Detect device compliance
Testing equipment (such as hydrostatic testing machine, ultrasonic flaw detector) must meet the requirements of the "Gas Cylinder Safety Technical Regulations", and pass the provincial metrology certification to ensure the validity and legal effect of the test data.
The inspection agency needs to obtain the special equipment inspection qualification, and the operators must pass professional training and hold certificates.
Detect environmental safety
The detection area needs to be equipped with an explosion-proof ventilation system, the acetylene concentration monitoring device needs to be linked to alarm in real time, and the leakage threshold is set to ≤10%REL.
2. Pre-test safety inspection process
Cylinder condition verification
Check the appearance of the cylinder for cracks, corrosion or deformation, and the weld of the cylinder body should be free of defects such as porosity and slag inclusion.
Confirm that the residual pressure of the cylinder ≥ 0.05MPa to prevent the risk of explosion caused by air mixing.
Equipment & Protective Readiness
Operators need to wear anti-static clothing, protective glasses and corrosion-resistant gloves, and it is forbidden to carry ignition sources or use non-explosion-proof tools in the testing area.
Check the tightness of the testing equipment circuits, sensors and valves to ensure that there is no leakage or gas leakage.
3. Safety control of the testing process
Pressure & Tightness Testing
Hydrostatic test: The pressure holding test is carried out at 1.5 times of the nominal working pressure (≥3MPa), the pressure holding time is ≥ 3 minutes, and the bottle body is observed to have no leakage or permanent deformation.
Air tightness test: The leakage point is detected by helium mass spectrometry leak detector, the leakage rate needs to be ≤1×10⁻⁶ Pa·m³/s, and the residual gas needs to be completely discharged after testing.
Internal defect detection
Ultrasonic flaw detector detects internal cracks, interlayers and other defects in the bottle body, with an accuracy of 0.1mm, and magnetic particle flaw detection is used for surface crack detection.
4. Data Logging and Exception Handling
Test results management
Record the test data (such as wall thickness loss, leakage rate, pressure value), if the wall thickness loss exceeds 10% of the original thickness or there are serious defects, the cylinder will be scrapped immediately.
The inspection report shall be stamped with the official seal of the inspection agency, archived for future reference and uploaded to the cylinder traceability system.
Emergency Handling
If there is a leak or abnormal pressure during the test, the emergency ventilation system will be activated immediately, the personnel will be evacuated and the air source will be turned off, and the faulty equipment will be isolated with explosion-proof tools.
5. Equipment maintenance and consumables management
Periodic maintenance requirements
Testing equipment needs to calibrate sensor accuracy on a quarterly basis, replace aging seals, valves and other consumables to ensure long-term reliability.
The residual liquid recovery device needs to clean the acetone solvent regularly to prevent the residue from clogging or polluting the environment
