FABRICATED PVC-U FITTINGS (SOCKETS) FOR POTABLE WATER SUPPLIES.

Transcription

1 BUREAU OF INDIAN STANDARDS (Eastern Region Office, Kolkata) DRAFT PRODUCT CERTIFICATION MANUAL FOR COMMENTS Our Ref: DDGE/22/IS 10124(pt-2) Dated: 20 Feb 2014 Sub: Draft manual for IS 10124(pt-2) This has reference to CMD circular CMD:1/31 dated:11 Nov 2013 on the above subject. In this connection, please find enclosed the draft product certification manuals as per details below: FABRICATED PVC-U FITTINGS (SOCKETS) FOR POTABLE WATER SUPPLIES. Kindly examine the draft product certification manual and forward your comments on the draft to ERO at in the format given below: Sl no Clause no/page no Comments Last date for comments: 10 March (Product Certification Officer) ERO

2 PRODUCT MANUAL FOR FABRICATED PVC-U FITTINGS (SOCKETS) FOR POTABLE WATER SUPPLIES AS PER IS (PART - 2) BUREAU OF INDIAN STANDARDS MANAK BHAWAN, 9, BAHADUR SHAH ZAFAR MARG, NEW DELHI

3 Amendment Sheet Sl.No. Amendment No. Reference No. Date of Issue Date of Implementation

4 Manual for Certification of Fabricated PVC-U Fittings (Sockets) for Potable Water Supplies as per IS (Part-2) FOREWARD The product certification scheme of the Bureau of Indian Standards, now under Bureau of Indian standards Act 1986, is in operation for more than four decades covering a wide variety of products. The wide experience in the area has brought a fair amount of rationalization in the certification process. This has resulted in the formulation of the Operation Manual for Product Certification (referred to as OMPC in this manual) prescribing rules and practices generally applicable to all products. Product related rules/guide lines are periodically issued to cover the specific requirements of different products. Still, in view of the wide spread of the certification operations, differences are found in the application of these guidelines in the BIS certification offices in different parts of the country. Therefore, it has been decided to bring out product manuals as guideline documents covering certification requirements of specific products/group of products. This Manual, one in the series, has been prepared to ensure uniformity in the certification practices in respect of Fabricated PVC-U Fittings (Sockets) for Potable Water Supplies covered by IS (Part-2). This manual is strictly an internal document intended for use by the certification marks officers of BIS. It takes into consideration the generally acceptable practices. However, it should not be treated as a replacement for referred standards and the relevant Scheme of Testing & Inspection (STI). The Standards and Documents (STI & others) referred in this manual are the latest ones at the time of preparation of this manual. However, latest version of the above documents shall always be referred.

5 Section Title TABLE OF CONTENTS I Product Description 1. Description of Product(s) 2. Latest Indian Standard Number with Product Title and Number of Amendments 3. List of referred Indian Standards for raw materials / components and test methods 4. Check-list for submission of an application for grant of licence II Raw Materials/ Components List of important Raw Materials / components, including those which are required to conform to the relevant Indian Standards III Manufacturing Process and Inprocess Quality Controls 1. Description of Manufacturing Process(es) 2. Infrastructure for production IV Certification Criteria 1. Identification of Critical Requirements of the Indian Standard 2. Scheme of Testing and Inspection 3. Marking Fee Rates 4. Grouping Guidelines, if any 5. Guidelines for writing Scope of Licence 6. Guidelines for Inclusion of new Varieties 7. Sample size, including guidelines for drawal of separate samples when samples are required to be sent to different labs for testing 8. Manner of Sealing of Sample(s) 9. Whether remnants of sample(s) are returnable / non-returnable, to be scrapped / used, to be deshaped before disposal In case of safety items), any other precaution required for dealing with remnants 10. Procedure to be followed for destroying / deshaping / recycling the product that does not meet the quality parameters during regular production 11. Whether MS can be/should be drawn V Inspection & Testing 1. Ideal qualification of BIS IO 2. Packing Material requirement (to be available in factory at all times) for Packing / Dispatch of Samples 3. List of required Test Equipment / Facilities with requirement and frequency of Calibration 4. Status of Test Facilities in BIS Labs and OSLs with Testing Charges, and approximate time required for testing by BIS labs / OSLs 5. Whether Grant of Licence will be based on: Factory testing basis or Independent testing basis or Mixed (factory testing basis plus independent testing of some raw materials) 6. Details of Tests to be carried out in the Factory in case of: Applicant Samples / Verification Samples Surveillance / Market Samples Raw Material Samples to be got tested, if any Annex-A : Draft Grouping Guidelines, Annex-B : List of Test Equipments & Calibration Frequency (To be Provided by CL) Annex-C : Testing Facility & Testing Charges

6 SECTION-I PRODUCT DESCRIPTION PVC- U sockets are used for jointing UPVC pipes using solvent cement or elastomeric sealing rings for achieving the desired length for laying and use for potable water supplies. There are various type of fittings which are fabricated from such UPVC pipes that are found to be conforming to IS Sockets are one of the types of the fittings used for jointing purpose. 1) : 2009 fabricated PVC-U fittings for potable water supplies Specification: Part 1 General requirements CHECKLIST FOR SUBMISSION OF APPLICATION FOR GRANT OF LICENCE Please refer to BIS website for the detailed checklist. PVC-U Socket for Solvent Cement Jointing The certification of this product is based on the general requirements of IS (Part-1) : 2009 and specific requirements of IS (Part-2) : These are the latest versions of these ISS at the time of preparation of this manual. The list of Indian standards referred to by IS (Part-2) are as given below: IS No. Title 4985 : 2000 Unplasticized PVC pipes for potable water supplies Specification (third revision) (Part Specification for

7 PVC-U Socket for Elastomeric Sealing Ring Joint SECTION - II RAW MATERIAL COMPONENTS As per IS (Part-1), the pipes used for fabrication of PVC-U fittings for potable water supplies shall conform to IS The maufacturer who produces fabricated PVC-U fittings shall either produce the UPVC pipes conforming to IS 4985 by itself or shall procure ISI marked pipes from another manufacturer. In almost all cases it is the UPVC pipe licensee for IS 4985, who seeks to obtain a licence for fabricated PVC-U fittings. For such manufactureres, the guidelines enshrined in the Manual for Cetification of Unplasticized PVC pipes for Potable Water Supplies as per IS 4985 (Doc. No. CMD-III/4985/1/Manual, Date of Issue 17 March 2008) shall be considered regarding use of raw materials. The pipes manufactured from such materials and found to be conforming to IS 4985 shall be used for manufacture of Fabricated PVC-U Sockets. It is clearly mentioned in the STI that the pipes that are ISI marked shall only be used from manufacturing fabricated PVC-U fittings for potable water supplies. SECTION-III MANUFACTURING PROCESS & IN-PROCESS CONTROL DESCRIPTION QUALITY Step-1: The fabriacted PVC-U sockets are manufactured by cutting the UPVC pipes conforming to IS 4985 of a required nominal diameter (DN) into

8 desired lengths. It may be borne in mind that the socket with a particular pressure rating is manufactured from the same class of pipe having the outiside diameter as equal to the nominal internal diameter of the socket. Step-2: In case of sockets for solvent cement jointing, the cut-length of the pipe is then heated using electrical heater or dipped in a hot liquid bath with suitable liquid, such as glycerine solution. As the ends of the cut-length of the pipe softens, it is pushed against a mandrel of required diameter and cooled. After the formation of the socket, the mandrel and the cut-length pipe are separeted by pulling them apart. The same process is also repeated on the opposite end as well. Step-3: In case of sockets for jointing pipes using elastomeric sealing rings, the cut-length of the pipes are heated at each end using electric heater and then placed on a belling machine, where the grooves are pressure formed by application of pneumatic pressure. Alternatively, a collapsible mandrel may be used for manufacture of grooved socket. This process comprises of heating of an end portion of the pipe to a temperature substantially above the glass transition temperature of amorphous plastic or the crystalline melting point of crystalline plastic, respectively, and pushing the heated end portion of the pipe onto a mandrel having a collapsible core for forming said groove. The core is in the expanded condition when the end portion is pushed onto the mandrel. After cooling of the end portion the core is collapsed and the socketed pipe is withdrawn from the mandrel. The sockets shall be manufactured according to the dimensions indicated in Table-1 and Table-2 of IS (Part-1) for Solvent Cement Jointing and Elastomeric Sealing Ring, respectively. INFRASTRUCTURE FOR PRODUCTION It may be clearly understood from the foregoing paragraphs on manufacturing

9 of the different types of sockets that the following infrastructure is required: a) Heating facility Electric Heater/ Hot Liquid Bath with suitable liquid b) Belling machine c) Alernately, manual belling can be used for sockets suitable for solvent cement jointing d) Belling Mandrels CRITICAL CONTROL POINTS In the manufacture of the sockets from the UPVC pipes conforming to IS 4985, the following points assume criticality in the manufacturing process: a) Uniform heating of the pipe ends before belling using the mandrels It must be ensured that the entire circular surface is unformly and homogenously heated before pressing against the mandrel for socket formation. Any deviation may lead to accumulation of material at certain places along the circumference increasing the wall thickness and thereby reducing the wall thickness at other places. This may lead to operational failure of the socket in withstanding the desired hydrostatic pressure while carrying the potable water. b) Co-axial position of the mandrel It must be ensured that the pipe end is co-axial w.r.t. the mandrel. If this is not ensured during belling operation, eccentricity of the socket ends would be observed, which may lead to failure in achieving straight length while laying of the pipes using jointing technique. Variation in wall thickness may also be observed along the circumference of the pipe. c) Out-of Square cross-section of pipe ends Any out-of square in the pipe ends may lead to insufficient penetration at certain positions of the mandrel and may lead to insufficient socket length.

10 SECTION IV CERTIFICATION CRITERIA CRITICAL REQUIREMENTS OF IS (PART-2) The general requirements of Fabricated PVC-U Fittings for Potable Water Supplies are mentioned in IS (Part-1). They are: a) Raw Material: The pipes used for manufacturing of the PVC-U fittings shall conform to IS b) Opacity: UPVC pipes exposed to sunlight may provide opportunities for microbiological growths. One purpose of using additives is to render the pipe opaque. However, formulations containing additives, such as plasticizers and lubricants, may support the growth of microorganisms. The standard stipulates that the wall of the pipe should be opaque enough not to transmit more than 0.2 percent of the visible light falling on it. The test for opacity should be conducted by the method prescribed in IS (Part 3). This test is also applicable for the sockets eventhough they are manufactured from the UPVC pipes conforming to IS It is because, the fabrication of the sockets from the pipe during belling operation leads to thinning of the wall at the neck. Lack of adequate wall thickness may make the fitting less opaque than the original pipe used for manufacturing of the socket. c) Short-term Hydraulic Test The sockets shall meet the hydraulic test requirement when tested as per Annex-A of IS (Part-1). A fitting shall be considered as having passed the test if it shows no sign of deterioration, leakage, fracture or other failure under specified condition. The test shall be repeated if the pipe bursts or if the solvent- welded joints leak.

11 The specific requirements of IS (Part-2) are limited to only the dimensional requirements. They are aslo critical as a lot would depend on the dimensions of the sockets while jointing the pipes and achieving the desired length without any performance failure of the joints while laying of them for potable water supplies. STI & Marking Fee: The present version of the Scheme of Testing & Inspection is STI/10124 (Part-1 to 13)/3, December The marking fee rates are as below: Unit : 1 Tonne Unit Rate: Rs MMF: Rs (SSI) & Rs (LS) Grouping Guidelines: At present, there are no grouping guidelines available for this product. However, the product variety is based on different size of the socket only. Although, pressure rating could also present a possibility of variety in the socket type, this could be ignored due to the fact that the manufacturer of the socket does not have the independence to produce sockets of different pressure ratings as they are basically based on the Class of the UPVC pipe used for manufacturing of the sockets. As the latest version of this ISS has aligned the sizes of sockets with that of IS 4985, hence, the grouping guidelines for permitting relaxation on sizes as per IS 4985 (Ref: CMD- III/16:4985 dated ) may also be logically extended to this product, for each type of socket (Solvent Cement Type/ Elastomeric Sealing Ring). However, this grouping guideline is a proposal which may be accepted subject to approval of CMD.The proposal for grouping guideline is at Annex-A of this document. Scope: While writing the scope of the licence, it should be ensured that the size of the socket and the type of jointing is clearly mentioned unambigously. The recommendation shall depend upon the availability of necessary manufacturing and testing faciliities available with the

12 licensee and the varieties of the samples tested. Inclusion of New Varieties: According to OMPC 2004, the criterion to determine whether the sample should be tested before the type or grade could be included is that the construction of the new type or grade should be distinctly different from those already included in the licence. In this case, the following shall constitute the criteria for considering distinctiveness of the product variety, which is not covered in the scope of the licence : 1. Size of socket outside the size group for which licence already exists 2. Type of socket, namely solvent cement jointing type or elastomeric sealing ring type The grouping guidelines at Annex-A of this manual may be followed. Sample Size: The number of samples that are required for complete testing of sockets is six (6). Apart from the sockets, a pipe of the same class and suitable outside diameter of mimimum length of 250mm is also required. The quantity of sample required is based on the following: Opacity and Dimensions 1 Socket Short term Hydrostatic Test 1 Socket is sufficient. However, in case of failure repeat test is required. Hence, more number of sockets may be required. It may be ensured from the laboratory, if separate cutlength (minimum 250mm) of pipe is required or not. Manner of Sealing: The purpose behing manner of sealing is to ensure no damage to the sample during transport, easy handling and prevent any chance of foul play in terms of alteration to the sample. Depending on the size of the socket, the socket sample may be sealed individually using thread or tied together. Remnants of the Sample: The remnants of the sample may be disposed off at the discretion of the laboratory, unless it is decided by the concerned lab

13 to take up QA testing on them. It is generally not required to return the remnants of sample to the firm, owing to the comparatively low cost of the product. However, if it is desired by the manufacturer that the remnants may be returned to it, the request may be considered and suitable indications be made in the test request to this effect. Method of Disposal of Sub-standard Product: During the manufacturing of the sockets, due to some reasons, product may not meet the requirements of the standard, which is found during the tests subsequently. In such cases, the marking on the product, which is generally done using stenciling, is required to be removed using a suitable petrochemical solution such as paint thinner, kerosene, petrol etc. Such material may be crushed into pieces and used for rework, at the discretion of the manufacturer of sockets, adhering to the provisions of relevant clause of IS However, suitable records may be maintaind as required by the STI. MARKET SAMPLE : MS shall be drawn, as it is possible. SECTION-V INSPECTION AND TESTING QUALIFICATION OF BIS IO: It is desired that the BIS IO shall be of Mechanical/Civil discipline REQUIREMENT OF PACKING MATERIAL This product does not require any special type of packing material for packing and dispatch of the samples. Availability of gunny bags would be sufficient for proper packing and dispatch of the samples. TEST EQUIPMENT AND CALIBRATION FREQUENCY The list of test equipments and frequency of calibration is provided at Annex-B. (To be provided by Central Laboratory)

14 TEST FACILITY AND TESTING CHARGES The testing facility in BIS labs and BIS Recognized laboratories (OSL) along with the testing charges are given in Annex-C. However, the latest status may be verified regarding availability of testing facility and recognition of the OSLs from BIS Intranet. The testing time would be approximately 2 weeks when considered with the fact that a failure in the Short Term Hydraulic test would require retest, which necessitates a 10day preconditioning of the joint as per note under A-4.2 of Annex-A of IS (Part-1). TESTING DURING OPERATION OF LICENCE During operation of licence, opacity and dimensional tests may be carried out in the factory. It shall also be ensured that the raw material (UPVC Pipes) is ISI marked. If possible, sample of UPVC Pipes may also be drawn as Market Sample, as per guidelines of OMPC. GRANT OF LICENCE Grant of licence and inclusion of new varieties are to be based on Independent Testing basis, considering the testing time which is, in any case, not less than 2 days.

15 ANNEX-A Proposed Grouping Guidelines for Fabricated PVC-U Fittings (Sockets) for Potable Water Supplies as per IS (Part-2). 1. IS (Part-2) covers Fabricated PVC-U Fittings (Sockets) for Potable Water Supplies of two types, namely: a) Socket for Solvent Cement Joint for sizes 20mm to 630mm b) Socket for Elastomeric Sealing Joint for sizes 63mm to 630mm 2. Accordingly, there are two distinct properties for variation in the product based on type of joint to be achieved and the size of the socket. 3. As these sockets are to be used with UPVC Pipes conforming to IS 4985, the grouping guidelines of IS 4985(Ref: CMD-III/16:4985 dated ), limited to providing relaxation on the size, may be adopted, which is given below: Type of Socket Joint Size Group-1 Size Group-2 Size Group-3 Solvent Cement Joint Elastomeric Sealing Ring Joint For the purpose of Grant of Licence/Inclusion, one sample from each size group for each type of socket joint shall be drawn for complete testing to cover all the sizes in a particular size group for a particular type of socket joint. 5. However, it shall be ensured that the firm is having complete manufacturing and testing facilities for the sizes intended to be covered in a size group. 6. During operation of licence, sample of other sizes shall be drawn on rotation to cover testing of all sizes of the product within a reasonable time. Submitted for approval of competent authority.

16 ANNEX C TESTING FACILITY AND TESTING CHARGES Testing Charges IS : 1988 Rs 450/- + material test as per IS 4985 BIS Laboratories IS Number :- IS : 1988 CL Mech P EROL Mech P Except opacity & hydraulic test NROL Mech N PBOL 2 nos. Mech P Dimensions only WROL 6 No. Mech P Opacity Test BIS Recognized Laboratories (Latest list to be verified from BIS Intranet) IS Number :- IS Part: 2 - FABRICATED PVC FITTINGS FOR POTABLE WATER SUPPLIES Sl Name of the Recognized Lab Code Testing Charges Remarks No. Laboratory 1 Central Institute of Plastics Engineering & Tech EPIP Complex, Hajipur Indl. Area Distt. - Vaishali Bihar Contact : Sh. D.P. Yadav, Chief Manager(TS) Tel : , Fax : Central Insitute of Plastics Engineeing & Tech P.O. Changsari, Dist. Kamrup Guwahati Assam Contact : Sh. Karl Murthy, Deputy Director & Head Tel : Rs.1350/- VCM content test subcontracted to Choksi Indore Rs.1,700/-

17 Fax : Central Institute of Plastics Eng & Technology City Centre, P.O. Debhog, Dist. Purba Medinipur Haldia West Bengal Contact : Mr.P.Poomalai, Dy Director Tel : Fax : Central Institute of Plastics Engg & Tech.(CIPET) 437/A, Hebbel Industrial Area Rs.1,350/- For sizes upto 355 mm nominal size Rs.875/- Mysore Karnataka Contact : Dr Sania Akhtar, Dy Director Tel : , Fax : Central Institure of Plastics Engg.& Tech.(CIPET) B-27, Amausi Indusrial Area Lucknow Uttar Pradesh Contact : Dr. Vijay Kumar, Dy.Director Tel : , Fax : Central Institute of Plastics & Engg. Tech.(CIPET) G. Sector, Govindpura, Industrial Area Bhopal Madhya Pradesh Contact : Shri P.K. Sahoo Chief Manager(P) Tel : , Fax : Central Institute of Plastics Engg. & Technology Rs.675/-Rs.1950/- extra for raw materisl test as per IS Rs. 1,350/-(For fittings); Rs /-(for raw material) Rs.875/- per sample; Rs.1000/- Min. Charges (VCM Content test subcontracted to Choksi Lab, Indore) Upto 400mm Nominal Dia ( Effect on water test

18 Plot No.J-3/2, MIDC Industrial Area, Chikalthana Aurangabad Maharashtra Contact : Sh.Sandesh Kr Jain, Manager(Project) M: Tel : , Fax : Central Institute of Plastics Engg. & Technology SP-1298, Sitapura Industrial Area, Phase-III Tonk Road Jaipur Rajasthan Contact : Mr. Lalit Guglani, Manager Tech. Services Tel : Fax : Rs.875/- in case of only one sample subcontracted to CIPET Bhopal)

19 PM/IS (Part-2)