DRAFT PRODUCT CERTIFICATION MANUAL FOR …MCM)IS 5312.pdf · This Product Manual is intended to...

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: [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 in case comments are lengthy and cannot be incorporated in

the table.

BUREAU OF INDIAN STANDARDS

PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-

RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312

(Part-I):2004

PREPARED BY:MDCH-2 APPROVED BY

2

PRODUCT MANUAL

ON

SWING CHECK TYPE REFLUX (NON-RETURN)

VALVES FOR WATER WORKS PURPOSES —

SPECIFICATION PART 1 SINGLE DOOR PATTERN

AS PER

IS 5312 (Part-I):2004




(Part-I):2004


3


MANAK BHAWAN,

9, B.S. ZAFAR MARG,

NEW DELHI-110 002

0.0-AMENDMENT SHEET

SR. NO. AMENDMENT NO. DATE PAGE NO CLAUSE NO




(Part-I):2004


4

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.




(Part-I):2004


5

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

QUALITY CONTROLS

10 to 12

IV CERTIFICATION CRITERIA 13 to 20

V INSPECTION AND TESTING 21 to 23




(Part-I):2004


6

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:

Size of Valve Nominal Pressure

(mm ) 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.




(Part-I):2004


7

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




(Part-I):2004


8

SECTION 1.4 A-

CHECK LIST FOR SUBMISSION OF AN APPLICATION FOR GRANT OF

LICENCE: See Annex B below




(Part-I):2004


9




(Part-I):2004


10

SECTION 1.4 B-




(Part-I):2004


11

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)


PREPARED BY:MDCH-2

12

PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON


(Part-I):2004

APPROVED BY






(Part-I):2004


13

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




(Part-I):2004


14

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.




(Part-I):2004


15

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

1

2

3

4

5

6

7

8

9

10

11

12

13

14.

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

Electric Grinder

Welding Machine

Cupola Furnace

Shot Blasting

Machine

Cutter Machine

Generator Set

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

50 to 600 mm

50 to 600 mm

8 to 10 Ton

Per Day

50 to 600 mm

2 Nos.

2 Nos.

3 Nos.

4 Nos.

2 Nos.

3 Nos.

2 Nos.

2 Nos.

3 Nos.

1 Nos.

1 Nos.

2 Nos.

1 No.

1 No.

For Turning, Facing,

Threading & Boring


Threading & Boring


Threading & Boring


Threading & Boring

For Drilling

For Drilling

For H.S.T. purpose

For Grinding Purpose

For Grinding Purpose

For Welding Purpose

For Melting Purpose

For Casting Finishing

Note: Adequate Electric Power and Water supply is required




(Part-I):2004


16

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)




(Part-I):2004


17




(Part-I):2004


18




(Part-I):2004


19




(Part-I):2004


20




(Part-I):2004


21

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




(Part-I):2004


22

SECTION 4.4 -GROUPING GUIDELINES:




(Part-I):2004


23

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.




(Part-I):2004


24

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




(Part-I):2004


25

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

5108204 Rs.1875/-

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

9126706 BIS Testing charges




(Part-I):2004


26

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)

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