DRAFT PRODUCT CERTIFICATION MANUAL FOR COMMENTS Our Ref.: NRO/CHBO(MCM) 13 Jan 2014 Please find enclosed the following draft certification manual: Swing Check Type Reflux (Non-Return) Valves For Water Works Purposes - Specification Part 1 Single Door Pattern as per IS 5312 (Part-I) : 2004 Kindly examine the draft product certification manual and forward your comments on the draft manuals. Last date for comments: 28 Jan 2014. Comments, if any, may please be made in the format as given below and mailed to CHBO(MCD) at the following email id: mdch2@bis.org.in. Sl. No. Name of RO / BO Clause/ Sub-clause Paragraph / Figure / Table Type of comment (General / Technical / Editorial) Comments Proposed Change Note: Separate sheets may be attached in case comments are lengthy and cannot be incorporated in the table.
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-RETURN) VALVES FOR WATER WORKS PURPOSES SPECIFICATION PART 1 SINGLE DOOR PATTERN AS PER IS 5312 2
BUREAU OF INDIAN STANDARDS MANAK BHAWAN, 9, B.S. ZAFAR MARG, NEW DELHI-110 002 0.0-AMENDMENT SHEET SR. NO. AMENDMENT NO. DATE PAGE NO CLAUSE NO 3
0.1-FOREWORD Swing Check Type Reflux (Non-Return)Valves for Water Works Purposesare very useful in preventing back flow of water to the pump. These valves have minimum head loss and can be very competitive in terms of long service life. These valves are very useful in waterworks pipelines to reduce hammer effect. Non slam and quick closing characteristics have made this product a very demandable one across markets. In the formulation of 5312 (Part-I)due weight age has been given to international co-ordination among the standards and practices prevailing in different countries in addition to relating it to the practices in the field in this country This product is manufactured all across the country; however maximum concentration of this Industry is in the states of Punjab. This Product Manual is intended to cover all elements needed for grant of a product certification licence and its continued operation providing reference material that can be used in all Regional / Branch Offices and by various applicants / licensees to ensure coherence of practice and transparency. 4
0.2 -TABLE OF CONTENTS SECTION CONTENT DETAIL PAGE NO I PRODUCT DESCRIPTION 5 to 8 II RAW MATERIAL/COMPONENTS 9 III MANUFACTURING PROCESS & IN-PROCESS 10 to 12 QUALITY CONTROLS IV CERTIFICATION CRITERIA 13 to 20 V INSPECTION AND TESTING 21 to 23 5
PRODUCT DESCRIPTION SECTION 1.1- DESCRIPTION OF PRODUCT IS 5312: (Part 1) covers requirement forflanged reflux valves of single door, swing check typeused for water works purposes of sizes 50 to 600 mm.double disc check and lift check valves are notcovered under the scope of this standard. As per IS 5312 (Part 1),Reflux valves shall be designated by nominal pressure (PN) defined as maximum permissible gauge working pressure (MPa). The nominal pressure for the varioussizes shall be as follows: 6 Size of Valve (mm ) Nominal Pressure M Pa 50 to 600 1.0 and 1.6 Reflux valves shall be of the following nominalsizes: 50, 65, 80,100,125,150, 200,250,300,350,400, 450,500 and 600 mm.
The nominal size shall refer to the nominal bore of the water way. The actual bore at any point shallnot be less than the nominal size given above. SECTION 1.2-LATEST INDIAN STANDARDS WITH PRODUCT TITLE AND NUMBER OF AMENDMENTS IS 5312 (Part 1): 2004 SWING CHECK TYPE REFLUX (NON-RETURN) VALVES FOR WATER WORKS PURPOSES SPECIFICATIONPART 1 SINGLE DOOR PATTERN AMENDMENTS --02 SECTION 1.3- LIST OF REFERRED INDIAN STANDARDS FOR RAW MATERIALS/COMPONENTS AND TEST METHODS LIST OF REFERRED INDIAN STANDARDS IS No.Title 210:1993 Grey iron castings Specification (fourth revision) 318:1981 Specification for leaded tin bronze ingots and castings (second revision) 320:1980 Specification for high tensile brass rods and sections (other than forging stock) second revision) 341:1973 Black Japan types A, B and C (first revision) 638:1979 Specification for sheet rubber jointing and rubber insertion jointing (second revision) 778:1984 Specification for copper alloy gate globe and check valves for water works purposes ~fourth revision) 1030:1998 Carbon steel castings for general engineering purposes (fifth revision) 1363 Hexagon head bolts, screws and nuts of product grade C (Part 1): 2002 Hexagon.head bolts (size range M 5 to M 64) (fourth revision) (Part 3): 1992 Hexagon nuts (size range M 5 to M 64) (third revision) 1538:1993 Cast iron pipe fittings for pressure pipes for water, gas and sewage (third revision) 1865:1991 Iron castings with spherical or nodular graphite (third revision) 2712:1998 Gaskets and pickings Compressed asbestos fiber jointing (third revision) 2932:1993 Enamel, synthetic, exterior (a) undercoating (b) finishing Specification (second revision) 3444:1999 Corrosion resistant alloy steel and nickel base castings for general applications Specification (third revision) 6603:2001 Stainless steel bars and flats Specification (/first revision) 9862:1981 Ready mixed paint, brushing, bituminous, black lead free, acid alkali, water and chlorine resisting 14329:1995 Malleable iron castings 7
SECTION 1.4 A- CHECK LIST FOR SUBMISSION OF AN APPLICATION FOR GRANT OF LICENCE: See Annex B below 8
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SECTION 1.4 B- 10
RAW MATERIALS/ COMPONENTS The materials used for the manufacture of different component parts shall conform to the requirementsgiven in Table 1 given below. Where alternative materials are specified in Table 1 these maybe used subject to theirstipulation in the contract or order. SECTION 2.1- LIST OF IMPORTATNT RAW MATERIALS/COMPONENTS INCLUDING THOSE WHICH ARE REQUIRED TO CONFORM TO RELEVANT INDIAN STANDARDS (See Table 1 below) 11
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON- 12
MANUFACTURING PROCESSES QUALITY CONTROLS SECTION 3.1-DESCRIPTION OF MANUFACTURING PROCESSES (TYPICAL) MANUFACTURING FLOW CHART (FOR C.I. & D.I.VALVES) Pattern Shop Foundry ( Moulding/Core Shop/ Casting) Fetling Shop (Grinding & Cutting) Q/A Inspection Shot Blasting Machine Shop (Machining) Q/A Department (Inspection) Hydrostatic Test Finishing Coating Q/A Inspection Dispatch 13
DESCRIPTION OF MANUFACTURING PROCESSES & QUALITY CONTROL In the Foundry sand moulds to be used in moulding boxes are prepared from the pattern by moulding machine & hand molding and cores are made from the core boxes of the items which are to be cast. The raw material metal is put into the crucible and melted using Cupola Furnace & Induction furnace. The material is melted and cast in the mould. During melting various fluxes and de- oxidizing chemicals are used. The casting is fettled, inspected grinded and then shot blasted. The cleaned casting is put to machining for different operations. After machining stage inspections are done. Hydro pressure test carried out followed by bituminous coating. After final inspection of the finished product, it is ready for dispatch. 14
SECTION 3.2 -INFRASTRUCTURES FOR PRODUCTION Following infrastructure is generally required for production of Swing Check Type Reflux (Non-Return) Valves For Water Works Purposes Specification Part 1 Single Door Pattern Sl.No. Machinery Make Capacity Number Remarks 2 3 4 5 6 7 8 1 Lathe Machine (12 Large) Lathe Machine (10 Large) Lathe Machine (8 Large) Lathe Machine (6 Large) Drill Machine (1 +1/2 Cap) Drill Machine Hydraulic Testing Machine With mandals Grinding Machine 80 to 600 mm 50 to 500 mm 50 to 500 mm 50 to 500 mm 50 to 600 mm 50 to 450 mm 50 to 600 mm 50 to 600 mm 2 Nos. 2 Nos. 3 Nos. 4 Nos. 2 Nos. 3 Nos. 2 Nos. 2 Nos. For Turning, Facing, Threading & Boring For Turning, Facing, Threading & Boring For Turning, Facing, Threading & Boring For Turning, Facing, Threading & Boring For Drilling For Drilling For H.S.T. purpose For Grinding Purpose 9 Electric Grinder 50 to 600 mm 3 Nos. For Grinding Purpose 10 Welding Machine 50 to 600 mm 1 Nos. For Welding Purpose 11 12 Cupola Furnace Shot Blasting Machine 8 to 10 Ton Per Day 1 Nos. 50 to 600 mm 2 Nos. For Melting Purpose For Casting Finishing 13 14. Cutter Machine Generator Set 1 No. 1 No. Note: Adequate Electric Power and Water supply is required 15
CERTIFICATION CRITERIA SECTION 4.1 -CRITICAL REQUIREMENTS OF THE INDIAN STANDARD (To be provided by CMD) SECTION 4.2 -SCHEME OF TESTING AND INSPECTION (See below) 16
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SECTION 4.3 -MARKING FEE RATES Description Value L S Marking Fee 34000 S S Marking Fee 29000 Unit 1 Valve Rate of one unit Rs. 3.5 21
SECTION 4.4 -GROUPING GUIDELINES: 22
SECTION 4.5 -GUIDELINES FOR WRITING SCOPE OF LICENCE "SWING CHECK TYPE REFLUX (NON-RETURN)VALVES FOR WATER WORKS PURPOSES SINGLE DOOR - WITHOUT BYE PASS WITH DOUBLE FLANGED ENDS CONSTRUCTION OF BODY IN PRESSURE PN 1.0 & 1.6 IN SIZES FROM 50 MM UPTO AND INCLUDING 125 MM; 150 MM UPTO AND INCLUDING 300 MM AND 350 MM UPTO AND INCLUDING 600 MM. SECTION 4.6 -GUIDELINES FOR INCLUSION OF NEW VARIETIES Same as Section 4.4 SECTION 4.7- SAMPLE SIZE Product-One sample comprising of one number of Swing Check Type Reflux (Non-Return) Valve of any size (see clause 6 & 8 of IS 5312 (Part 1): 2004. SECTION 4.8 -MANNER OF SEALING THE SAMPLE Samples may be wrapped with suitable packing material, labeled and wax sealed or as an alternate code no and signatures of IO may be marked with a permanent marker pen on the product. SECTION 4.9 -REMNANTS ARE RETURNABLE/NON-RETURNABLE TO BE SCRAPPED/USED OR TO BE DESHAPED DISPOSAL IN CASE OFSAFETY ITEMS Sample is normally consumed in testing and Remnants are not returnable and may be suitably disposed off by the laboratory. SECTION 4.10- PROCEDURE TO BE FOLLOWED FOR DESTROYING/ DESHAPING/ RECYCLING THE PRODUCT THAT DOES NOT MEET THE QUALITY PARAMETERS DURING REGULAR PRODUCTION BIS Standard Mark to be marked only after ascertaining the quality of the material after testing as per Indian standard and STI. 23
INSPECTION AND TESTING SECTION 5.1-PACKING MATERIAL REQUIRED FOR PKG/DISPATCH OF SAMPLE Any suitable material may be used for wrapping the sample to avoid any damage during transit. SECTION 5.2-LIST OF REQUIRED TEST EQUIPMENT/FACILITIES WITH REQUIREMENT & FREQUENCY OF CALIBRATION (To be provided by CL) SECTION 5.3 -STATUS OF TEST FACILITIES IN BIS LAB AND OSL WITH TESTING CHARGES AND APPROXIMATE TIME REQUIRED FOR TESTING For latest information, please check the BIS web site www.bis.org.in or click the following link http://www.bis.org.in/lab/osl_query.asp?form_is=5312 Pt.(I) &Submit=Run+Query 24
List of BIS Laboratories Lab Quantity Lab Type Testing Facility Remarks IS Number :- IS 5312-1 : 2004 BNBOL 1No Mech P Ex material test NROL 1 No Mech P except Hydrostatic above 300 mm & Chemical IS Number :- IS 5312-2 : 1986 BNBOL 1No Mech P Ex material test IS No. Testing Charges Remarks IS 5312-1 : 1984 Rs 1200/- Excluding Material Material charges as per relevant ISS Testing Facility:: C=Complete Test facility / P=Partial Test Facility/ N=No Test Facility List of Outside Recognized Laboratories (As on 19 11 2013) IS Number :- IS 5312 Part: 1 - SWING CHECK TYPE REFLUX (NON-RETURN) VALVE FOR WATER WORK PURPOSES PT-1 SINGLE DOOR PATTERN Sl No. Name of the Recognized Laboratory Lab Code Testing Charges Remarks 1 MSME Testing Centre M/o Micro,Small & Medium Enterprises,Govt.of India 111&112 B.T. Road Kolkata-700108 West Bengal Contact : Sh. P. Ray, Director Tel : 033-25770686/2482 Fax : 033-25771353 2 M/s United Solutions Private Limited C-245, Village: Allour, Bhadla Road, Khanna Distt.- Ludhiana Ludhiana-141402 Contact : Shri Manoj Kumar, Managing Director Tel : 09417010448 Fax : 01628-238108 25 5108204 Rs.1875/- 9126706 BIS Testing charges
SECTION 5.4 -WHETHER GRANT OF LICENCE WILL BE BASED ON FACTORY TESTING BASIS---------------------------------------------No INDEPENDENT TESTING BASIS--------------------------------------Yes MIXED BASIS (FACTORY TESTING OF PRODUCTPLUS INDEPENDENT TESTING OF SOME RAW MATERIALS)----------No SECTION 5.5 -DETAILS OF TESTS TO BE CARRIED OUT IN FACTORY IN CASE OF APPLICANT/VERIFICATION SAMPLES Dimensions and tolerances as per clause 6.2 of IS 5312 ( Part-1) Hydrostatic Body Test as per clause 8.2&Hydrostatic Seat Testas per clause 8.3 of IS 5312 ( Part-1) SURVEILLANCE SAMPLES Dimensions and tolerances as per clause 6.2 of IS 5312 ( Part-1) Hydrostatic Body Test as per clause 8.2 & Hydrostatic Seat Test as per clause 8.3 of IS 5312 ( Part-1) RAW MATERIAL SAMPLES TO BE GOT TESTED IF ANY -- As per clause 5, table 1 of IS 5312 ( Part-1) 26