Advanced Manufacturing Techniques for High-Pressure Gas Cylinders
EKC International is a leader in making high-pressure seamless gas cylinders with a commitment to precision and innovation. EKC International makes high-quality cylinders using advanced technology and skilled technicians. EKC’s process for making cylinders shows excellence and reliability.
Tube Cutting
The process begins with the thorough selection of quality seamless tubes, which will then be accurately cut to length through highly advanced cutting facilities. Each tube will thus be cut to the exact size required for the following processing stage.
Bottom Forming
In the bottom forming stage, the cut tubes undergo shaping to create a stable and robust base. This vital process forms the bottom of the tube so that it can resist high pressure, securing the cylinder to the bottom.
Bottom Pressing
For industrial cylinders, an additional bottom-pressing step is performed. This involves applying significant pressure to shape and reinforce the bottom of the cylinder, ensuring it meets the requirements for industrial usage.
Inside Bottom Milling
The inside base of the cylinder should be machined with utmost accuracy to result in a smooth, even surface – which is integral for the structure and functioning of the cylinder.
Neck Forming
The open end of the tube is shaped into the neck through a series of forming operations, ensuring uniformity and the ability to accommodate the required fittings.
Neck Drilling
The accurate drilling makes way for the valves and other accessories, which are required to ensure that the cylinder works well and is fully safe.
Heat Treatment
The cylinders are heat-treated, to enhance their mechanical properties, hence providing improved strength, duration, and overall performance.
Hardness Check
After heat treatment, the hardness in cylinders are checked to confirm that they meet standards and that the material does take the properties desired for it.
Neck Threading
Neck threading is an essential activity in cylinder manufacturing as valves and other accessories are connected to cylinder threads. It is done with high precision, so the connection is firm, not letting gas out.
Ultrasonic Testing
This non-destructive technique is always employed to detect any type of flaw or defect within the material, thus ensuring safety and integrity for each cylinder before the material is moved on to the following process.
Hydro Stretch Testing
Cylinders are passed through high-pressure water to check leak-tightness and for structural assurance that they can successfully hold the required pressure without failure.
Leakage Air Testing
The cylinder is pressurized with air at the actual working pressure of the cylinder to check for any kind of leakage and to confirm that the cylinder is fit for use.
Internal & External Shot Blasting
Blasting of abrasive materials at the surface of the cylinder to clean the impurities or scale on the internal and external surfaces to make them ready for further processing.
Stamping and Painting
Stamped with identification and certification marks after cleaning. They are later painted (powder coated) for corrosion resistance and to produce the end product; quality control is given by checking verification of uniform and adequate paint coating.
Inspection of Finished Product
All the cylinders are subjected to exhaustive final inspection to ensure conformance to the quality and safety standards. Upon approval, they are sent for dispatch for use in industrial and medical gas applications.
Conclusion
With the most careful and innovative process, EKC International ensures the best of standards in their cylinders to bring forth reliable and safe performance through all possible applications. Industrial or medical cylinders, be either, EKC cylinders are a mark of quality and excellence.
