DRAFT PRODUCT CERTIFICATION MANUAL FOR COMMENTS · 1Brass gravity die castings (ingots and...

DRAFT PRODUCT CERTIFICATION MANUAL FOR COMMENTS Our Ref.: NRO/CHBO(MCM) 05 Dec 2013 Please find enclosed the following draft certification manual: Copper Alloy Gate, Globe and Check Valves for Waterworks Purposes as per IS 778: 1984 Kindly examine the draft product certification manual and forward your comments on the draft manuals. Last date for comments: 20 Dec 2013. Comments, if any, may please be made in the format as given below and mailed to CHBO (MCM) at the following email id: [email protected]. 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 incase comments are lengthy and cannot be incorporated in the table.

PRODUCT MANUAL

ON

COPPER ALLOY GATE, GLOBE AND CHECK

VALVES FOR WATERWORKS PURPOSES As per IS 778: 1984

BUREAU OF INDIAN STANDARDS MANAK BHAWAN,

9, B.S. ZAFAR MARG, NEW DELHI-110 002

BUREAU OF INDIAN STANDARDS

Product Manual for Copper Alloy Gate, Globe And Check Valves For Waterworks Purposes as per IS: 778 – 1984

PREPARED BY : MDCH-2 APPROVED BY

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Amendment Sheet: To ensure that this Product Manual contains a complete record of Amendments, this Amendment sheet shall be maintained in the Product Manual.

AMENDMENT NO. DATE PAGE NO. DATE




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Foreword This product manual contains the description, manufacturing, and testing of copper alloy gate, globe and check valves for waterworks purposes (Fourth Revision ) as per IS : 778 - 1984. Guidelines for Grant of ISI licence for an applicant is also described in this manual. Grouping guidelines, sample size for testing, information about laboratories where the product can be got tested for the purpose of Grant of Licence etc. are described in the manual for the easiness of a new applicant as well as existing licensee.




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Table of Contents Sr no. Content Page no

1. Section I 5-11 2. Section II 12-12 3. Section III 13-14 4. Section IV 15-22 5. Section V 23-26




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Section I: Product Description




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1. Description of product (s)

1.0 Gate Valve - A valve through which the flow of fluid is controlled by means of a gate in the form of a wedge or disc between the body ends which are in line with each other; the gate is actuated by a stem whose axis is at right angles to that of the body ends. In the gate valves, the fluid pressure acts on one side of the gate and there is no change in the direction of flow.

1.1 Globe Valve ( or Screwdown Stop Valve) - A valve having generally a spherical body in which the body ends are in line with each other and the disc is lifted from or lowered on to the body seat by a stem whose axis is at right angles to that of the body ends. In globe valves, the pressure acts on the underside of the valve disc and there is a change of direction of flow inside the valve body.

1.2 Anile Valve - A valve having generally a spherical body in which the body ends are at right angles to each other and the disc is lifted from or lowered on the body seat by a stem whose axis is in line with that of one body end.

1.3 Check Valve ( or Non-return Valve) - A valve which permits fluid to flow in one direction but checks all return flow. It is operated by pressure alone, having no external means of control. The flow is controlled by means of a disc raising and falling on to a seat with the fluid pressure ( lift check ); the return may sometimes be added by a spring ( spring loaded check). The flow may also be controlled by means ef a flap swinging up and down with pressure on to a seat ( swing check ).

2. Latest Indian Standard Number with Product title and number of

Amendments

COPPER ALLOY GATE, GLOBE AND CHECK VALVES FOR WATERWORKS PURPOSES (FOURTH REVISION) AS PER IS: 778 – 1984 No of Amendments: 04




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3. List of referred Indian Standards for raw materials/ components and test methods

The materials used for the manufacture of different component parts of the valves shall conform to the requirements given in Table 1 of IS 778:1984

TABLE 1 MATERIALS FOR COMPONENT PARTS OF GATE GLOBE AND CHECK VALVES

SL COMPONENT MATBRIAL CONFORMING TO No.

(I) (2) (3) (4) i) Body a) Brass DCB 2 of IS: 1264-19891

b) Leaded tin .LTB 2 of IS: 318.19812 bronze ii) Bonnet or cover a) Leaded tin do bronze b) Forged brass FLB of IS 6912:19856 c) Brass DCB 2 of IS : 1264-19891 iii) Stuffing box, disc a) Leaded tin bronze LTB 2 of IS : 318-19812 hinge, check nut, b) Extruded brass rod Grade 1 or Grade 2 stem nut t disc ( Half hard ) of retaining nut, IS : 319-19894 gland, gland nut, C) Forged brass FLB of IS 6912:19856 gland flange, body seat rings d) Brass DCB 2 of and disc or wedge IS .: 1264-198 11 facing rings (where

renewable)

iv) Stem, hinge pin and a) Extruded brass Grade 2 ( Half hard) plug rod of IS : 319-19894 b) High-tensile brass HT l or HT 2 of IS : 320-19806 FHTB 1 and FHTB 2 of IS : 6912-19854 c) Forged brass FLB of IS 6912:19856

d brass DCB 2 of IS: 1264-19891

v) Ball ( for ball type Chromium steel IS : 4398-19727 check valves) vi) Bolts, nuts Mild steel Property clauses 4.6 and 4 of IS : 1367-19678 vii) Handwheel Cast iron FG 200 of IS : 210-19789 viii) Gasket Compressed Grade C of asbestos fibre IS: 2712-197110

ix) Gland packing a) Hemp and jute IS : 5414-196911

b) Asbestos IS : 4687-198012




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x) Spring Phosphor bronze IS : 7608-198713 wire

xi) Seating ring Synthetic rubber IS : 5192-197514

1Brass gravity die castings (ingots and castings)- Specification (third revision) 2Specification for leaded tin bronze, ingots and castings ( second revision ). 3Specification for brass bars, rods and sections suitab Ie for forging (first revision ). 4 Brass gravity die castings (ingots and castings)- Specification (third revision) 5Specification for high tensile brass rods and sections ( second revision ). 6 Brass gravity die castings (ingots and castings)- Specification (third revision) 7Specification for carbon-chromium steel for the manufacture of balls, rollers and bearing races ( first revision ). 8Specitlcation for technical supply conditions for threaded fasteners (fi rst revision j. 9Specification for grey iron castings ( third revision ). 10Specification for compressed asbestos fibre jointing ( second revision ). 11Specification for gland packing, jute and hemp. 12Specification for gland packing asbestos. 13 Brass gravity die castings (ingots and castings)- Specification (third revision) 14Specification for vulcanized natural rubber based compounds ( first revision ). 4. Check –List for submission of an application for grant of licence a) Check list for application to be submitted by applicant to BIS while applying for BIS licence (See Annex B)




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b) List of documents to be attached with application




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Section II: Raw Materials/ Components (Please refer Clause 4.0 of Section I)




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Section III: Manufacturing Process and In-process Quality Controls




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1. Description of manufacturing process

A typical flow chart indicating manufacturing process is depicted below: CASTING SHOTNBLASTING MACHINING FITTING (HST) CHECKING PAINTING PACKING DESPATCH

2. Infrastructure for production A Unit may need following machineries to in manufacturing of Gate, Globe and Check Valves:

1. Lathe machine 2. Cutter 3. Grinding Machine 4. Buff Machine 5. Drill machine 6. Electric Weighing Machine 7. Patterns for different sizes




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Section IV: Certification Criteria




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1. Identification of critical requirements of the Indian standard (To be identified by CMD)




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2. Scheme of Testing and Inspection:




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3.0 Marking fee rate: The following rate of marking fee is applicable for a licencee: i) Rate of marking fee: Unit- 1 Pieces Rs 0.55 for all units ii) Minimum marking fee Rs. 29000 (for Small Scale Industries) / Rs 34000/-(for Large Scale Industries) for one operative year payable in advance which will be carried to next renewals. iii) Actual marking fee for the first nine months of the operative period calculated on unit rate basis on the production marked or the minimum marking fee whichever is higher shall be payable by the licencee. 4.0 Grouping Guideline:- As per the decision taken during the meeting of BIS with Punjab Valves Manufacturers Association held at Jalandhar on 20-10-1995 with regard to Groupings and Sampling procedure for considering grant of licence/Inclusions up to 50 mm, three samples of size 15 mm, 25 mm and 50 mm of each type of valves shall be drawn and got tested and for above 50 mm, one additional sample, preferably of highest size offered at a time, shall be drawn and got tested. 5.0 Guideline for writing scope of licence:- Scope of licence may be written as "Recommended Grant of Licence for Nominal Sizes- 15-100mm, Classification of Valve – Class I/Class II, Type- Gate/Globe/Check Valve Solid/ Split Wedge Screwed/ Flanged ends Integral/ Renewable Body Seats

Screwed-in / Screwed-on / Bolted Bonnets, …..etc”




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6.0 Guidelines for inclusion of new varieties:- Please refer Cl 4 of Section IV above 7.0 Sample size : - One valve + approx 100 g drillings for material test 8.0 Manner of sealing the sample:- Wrapped in Poly bag and packed in corrugated box and wax sealed 9.0 Whether remnants of the sample are returnable/non-returnable: Returnable 10. Procedure to be followed for destroying the product that does not meet the quality parameters during regular production: If the BIS Standard Mark is die punched or cast on the Valve body, the same is to be removed by grinding or body to be re-casted. If transfix label is affixed then the same shall be removed and the body shall be re-casted.




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Section V: Inspection and testing




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1.0 Packing material requirement (to be available in factory at all times) for packing/dispatch of samples:- Wrapped in Poly bag and packed in corrugated box and wax sealed 2.0 List of required test equipment/facilities with requirement and frequency of calibration: (To be decided by Central Lab, Sahibabad) Status of test facilities in BIS labs and OSLs with testing charges and approximate time required for testing:-

List of BIS Laboratories

Lab Quantity Testing Facility Approx time required for testing

CL 1no+raw mat+100g drill C - EROL 1no+raw mat+100g drill P - NROL 1 no C - SROL 1no+raw mat P -

IS No. Testing Charges Remarks IS 778 : 1984 Rs 1125/- material as per ref ISS

Testing Facility:: C=Complete Test facility / P=Partial Test Facility/ N=No Test Facility




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List of Outside Recognized Laboratories (As on 19 11 2013)

IS 778 - COPPER ALLOY GATE, GLOBE AND CHECK VALVES FOR WATER WORKS PURPOSES

Sl No. Name of the Recognized Laboratory Lab Code Testing Charges Approx time required

for testing

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Shriram Institute For Industrial Research 19, University Road, P.B.No. 2122, Delhi-110007 Delhi Contact : Director Tel : 27667267,27667860 Fax : 91-011-27667676

8102006

Rs.15000/- efffective from 21.03.2013

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National Test House (NR) Kamla Nehru Nagar Ghaziabad-201001 Uttar Pradesh Contact : The Director Tel : 0120-2789493 Fax : 0120-2789883, 13

8101304

Rs.5500/-

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Bharat Test House, Wazirpur 26, Wazirpur Industrial Area, Near Krish Maruti Service Station,Wazirpur Delhi-110052 Delhi Contact : Shri. Rajiv Gupta(C.E.O.) Tel : 011-27675696 Fax : 011-43851204

8125206

BIS Testing Charges

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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

9126706

BIS Testing charges -




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3.0 Whether grant of licence will be based on :

Factory testing basis X Independent testing basis √ Mixed(Factory testing basis plus Independent testing basis ) X 4.0 Details of tests to be carried out in the factory in case of: Applicant samples/verification sample-

As per PARA 5-9 of STI Survelliance/Market samples-

As per PARA 5-9 of STI Raw material samples to be got tested, if any

As per Table 1 of STI

DRAFT PRODUCT CERTIFICATION MANUAL FOR COMMENTS · 1Brass gravity die castings (ingots and...

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