BUREAU OF INDIAN STANDARDS (Southern Regional Office) Our Ref: 60/CM 1 10 Dec 2013

Transcription

1 (Southern Regional Office) Our Ref: 60/CM 1 10 Dec 2013 Subject: Preparation & Review of Product Manuals for Product Certification This has reference to CMD-I s circular CMD-1/31 dated 11 Nov 2013 on the above subject. In this connection, the draft Product Manual in respect of IS 398 allotted to SRO has been prepared. The same is attached herewith for hosting on the BIS Intranet for inviting suggestions and comments for a period of 15 days. The comments may be sent to SRO/ CNBO(MCM). Encl: a/a (H.L. Upendar) DDGS HITSD BIS HQ E. DEVENDAR Scientist G & Deputy Director General (South) Bureau of Indian Standards Southern Regional Office IV Cross Road, C.I.T. Campus Tharamani, Chennai ddgs@bis.org.in Phone: Fax:

2 ON Aluminium alloy stranded conductors (Aluminium- Magnesium-Silicon type) for overhead transmission purposes as per IS 398 (Pt-4):1994 These procedures and the information contained therein are the property of BIS. It must not be reproduced either in part or in full or otherwise disclosed without prior permission in writing from The Director General, BIS. This product manual is issued by CMD-III under the authority of The Director General, BIS. Issue No. 1 Issue Date December 2013 Copy No. Holder

3 AMENDMENT SHEET 0.1 AMENDMENT SHEET BUREAU OF INDIAN Page 1 of 1 DOC NO:PM/398-4/001 P.K.GAMBHIR,Sc-G & CHIEF (CERTIFICATION) To ensure that each copy of this compiled product manual on Aluminium alloy stranded conductors (Aluminium-Magnesium-Silicon type) for overhead transmission purposes contain a complete record of amendments, this Amendment Sheet shall be updated and issued with each set of revised/additional manual. Sl. NO Date Brief Details Issue No.

4 FOREWORD 1.0 FOREWORD BUREAU OF INDIAN Page 1 of 1 DOC NO:PM/398-4/002 P.K.GAMBHIR,Sc-G & CHIEF (CERTIFICATION) 1.1 BIS has published an Indian Standard on Aluminium alloy stranded conductors (Aluminium-Magnesium-Silicon type) for overhead transmission purposes namely IS 398 (Pt-4):1994. This standard covers the requirements and tests for aluminium alloy stranded conductors of the aluminium-magnesium-silicon type for overhead power transmission purposes. The product is under voluntary certification.the Standard was first published in the year Since then the standard has undergone 3 revisions. 1.2 Though the standard was first published long back, the absence of any specific documented guidelines regarding operation of the certification schemes for the product, different approaches were followed by the different ROs/ BOs, for all these years, thus leading to confusion amongst the Marks Departments of the Bureau. Hence a strong need was felt for formulation and implementation of a Product Specific Manual for ensuring uniformity in operation of the certification schemes for aluminium alloy stranded conductors of the aluminium-magnesiumsilicon type for overhead power transmission purposes. 1.3 This Manual provides General Guidelines on various aspects related to certification of the product. The Manual gives illustrative examples of the process flow diagrams of manufacturing, plant and machinery, the STI, MF, grouping guidelines, the samples and the sample sizes, the various labs available for testing along with their testing charges. This manual provides a ready reckoner for the IOs to check facilities for each of the requirements against the method given under the ISS. 1.4 Various guidelines have been issued from time to time regarding Indian Standard/STI and related certification operational issues. Efforts have been made to incorporate major decisions in this manual, however, the provision of ISS, STI and policy guidelines would prevail over the manual, incase of any difference in interpretation. 1.5 This Manual is to be used along with IS 398(Pt-4) and STI amended/revised from time to time. 1.6 This document is intended for internal use by BIS officers only. Suggestions for any improvement in the manual may be sent to CMD for consideration.

5 TABLE OF CONTENTS 0.1 CONTENTS BUREAU OF INDIAN Page 1 of 1 DOC NO:PM/398-4/003 P.K.GAMBHIR,Sc-G & CHIEF (CERTIFICATION) SL.NO. DOCUMENT NO. TITLE 1. PM/398-4/001 AMENDMENT SHEET 2. PM/398-4/002 FOREWORD 3. PM/398-4/003 TABLE OF CONTENTS 4. PM/398-4/004 SECTION I: PRODUCT DESCRIPTION 5. PM/398-4/005 SECTION II: RAW MATERIALS/ COMPONENTS 6. PM/398-4/006 SECTION III: MANUFACTURING PROCESS AND IN- PROCESS QUALITY CONTROLS 7. PM/398-4/007 SECTION IV: CERTIFICATION CRITERIA 8. PM/398-4/008 SECTION V: INSPECTION AND TESTING

6 SECTION-I: PRODUCT DESCRIPTION Page 1 of 1 DOC NO:PM/398-4/004 P.K.GAMBHIR,Sc-G & CHIEF (CERTIFICATION) 1.0 DESCRIPTION OF PRODUCT 1.1 "Aluminium alloy stranded conductors (Aluminium-Magnesium-Silicon type) for overhead transmission purposes" is used in the transmission and distribution of electrical power from one place to the other. The Aluminium-Magnesium-Silicon alloy wires are heat treated to reach high breaking load so that they do not require any steel reinforcement. 2.0 Latest Indian Standard 2.1 Latest ISS:IS 398 (Pt-4): Product: Aluminium Conductors for overhead transmission purposes. Part 4 Aluminium alloy stranded conductors (Aluminium- Magnesium- Silicon type)-specification 2.3 Amendments: LIST OF REFERRED FOR RAW MATERIALS AND TEST METHOD 3.1 Raw material:is 9997:1991- Aluminium alloy redraw rods for electrical purposes 3.2 Test Methods:Nil 4.0 CHECK-LIST FOR SUBMISSION OF AN APPLICATION FOR GRANT OF LICENCE (Annex-B of CMD circular CMD-1/31 dt enclosed)

7 SECTION-II: RAW MATERIALS Page 1 of 1 DOC NO:PM/398-4/005 P.K.GAMBHIR,Sc-G & CHIEF (CERTIFICATION) 1.0 LIST OF IMPORTANT RAW MATERIALS WHICH ARE REQUIRED TO CONFORM TO THE RELEVANT ISS 1.1 The Aluminium-Magnesium-Silicon alloy wires used in the manufacture of the conductors have to meet the requirements of IS 9997:1991- Aluminium alloy redraw rods for electrical purposes. The same should be ensured by the manufacturer through test certificates from the supplier. No further testing is necessary.

8 SECTION-III: MANUFACTURIN PROCESS & IN-PROCESS QUALITY CONTROLS Page 1 of 2 DOC NO:PM/398-4/006 P.K.GAMBHIR,Sc-G & CHIEF (CERTIFICATION) 1.0 DESCRIPTION OF MANUFACTURING PROCESS 1.1 A typical process flow chart in the manufacture of Aluminium alloy stranded conductors (Aluminium-Magnesium-Silicon type) for overhead transmission purposes along with the in process controls are given below: Drawing of Aluminium alloy wire into intermediate sizes Solution Treated: Heated to C, soaked in that temperature for minutes and quenched in water without loss of time. After 24 hours wire drawn to final size and rolled in bobbins Bobbins kept in ageing oven and heated to C and soaked for 4-6 hours Tested for conformity to the ISS for before stranding requirements Bobbins stranded in stranding machine to form the aluminum alloy conductor into wooden/steel drums Tested for conformity to the ISS for after stranding requirements Markings done on the drums Despatched

9 SECTION-III: MANUFACTURIN PROCESS & IN-PROCESS QUALITY CONTROLS Page 2 of 2 DOC NO:PM/398-4/006 P.K.GAMBHIR,Sc-G & CHIEF (CERTIFICATION) 2.0 INFRASTRUCTURE FOR PRODUCTION 2.1 The following are the minimum list of machinery needed for the manufacture of Aluminium alloy stranded conductors (Aluminium-Magnesium-Silicon type) for overhead transmission purposes. 1. Wire Drawing machine-bull Block 2. Wire Drawing Machine to suitable sizes 3. Pointing Machine 4. Spooling Machine 5. Solution treatment tank with quenching furnace 6. Ageing Electrical Oven 7. Stranding machine of required size 8. Butt welding machine 9. Weighing machine, capacity atleast 2 MT

10 SECTION-IV: CERTIFICATION CRITERIA Page 1 of 4 DOC NO:PM/398-4/007 SH.P.K.GAMBHIR,Sc-G & CHIEF (CERTIFICATION) 1.0 IDENTIFICATION OF CRITICAL REQUIREMENTS OF THE INDIAN STANDARD 1.1 The following are the critical requirements of the ISS on the stranded conductors: Cl nominal size (diameter), Cl &12.4-Resistance, Cl.9-Stranding, Cl Breaking load and Cl.12.3-Elongation 2.0 SCHEME OF TESTING AND INSPECTION (STI/398(4)/3/JULY 2000 enclosed)

11 SECTION-IV: CERTIFICATION CRITERIA 3.0 MARKING FEE RATES Minimum Marking Fee : Rs.29,000/- for SSI Rs.34,000/- for LSI or Rs.34p60 for each MT of production (whichever is higher) Page 2 of 4 DOC NO:PM/398-4/007 SH.P.K.GAMBHIR,Sc-G & CHIEF (CERTIFICATION) 4.0 GROUPING GUIDELINES 4.1 No grouping guidelines exist. For the purpose of uniformity the following grouping guideline should be followed: 4.2 Sample(s) of any construction of conductor shall be subjected to testing before considering inclusion/grant of licence for that particular group of conductors. S.No. Group Actual Area [Refer Col(2),Table 2 of IS 398(Pt.4):1994] 1 A Up to and including 100 mm 2 2 B Above 100 mm Firm to declare size of conductors they intend to cover in the licence. IO may accordingly verify their manufacturing capability and availability of testing facilities to restrict size of conductors and may recommend grant of licence/inclusion. 4.4 Any size of the conductor, preferably maximum size intended to be covered in the licence may be drawn of each group. 4.5 Whenever, failure has been reported of any size, Licence to be granted only for the particular group of sizes where the sample of that particular group passes. 5.0 GUIDELINES FOR WRITING THE SCOPE OF THE LICENCE 5.1 Licence document/endorsement shall clearly indicate the description of the sizes covered in the licence. Open licence shall not be granted. The licence may be granted as follows

12 SECTION-IV: CERTIFICATION CRITERIA Page 3 of 4 DOC NO:PM/398-4/007 SH.P.K.GAMBHIR,Sc-G & CHIEF (CERTIFICATION) Aluminium alloy stranded conductors (Aluminium-Magnesium-Silicon type) for overhead transmission purposes, Sizes: Up to and including mm 2 actual area as per IS 398 (Pt-4):1994" 6.0 GUIDELINES FOR INCLUSION OF NEW VARIETIES 6.1 The procedures as mentioned at 4.2 to 4.5 may be followed. 6.2 If the licence is already granted, for only one particular size which has been tested, before issuing of these guidelines, inclusion of the entire sizes of the conductors for which manufacturing /testing facilities are available may be considered by the BO based on the merits of the case without any further testing. Future inclusions should be done only by testing fresh samples of higher size of conductor keeping the guidelines in mind. 7.0 SAMPLE SIZE, INCLUDING GUIDELINES FOR DRAWAL OF SEPARATE SAMPLES WHEN SAMPLES ARE REQUIRED TO BE SENT TO DIFFERENT LABS FOR TESTING 7.1 The following are the minimum sample size for complete testing of the product as per the grouping guideline mentioned at 4.2 both for the purpose of grant of licence/inclusion Aluminium alloy wire before stranding -5 m Aluminium alloy stranded conductors - 5 m No testing of rawmaterial aluminium alloy rods is necessary. 7.2 The nature of testing being only for mechanical and electrical properties, the necessity to send the samples to different labs do not arise. 7.3 A counter sample of the same batch and size is also drawn, sealed and kept in the factory. 8.0 MANNER OF SEALING OF SAMPLES 8.1 The sample may be wound and wrapped with polythene or suitable sheet and tied to a tag and wax sealed with BIS brass seal. 9.0 WHETHER REMNANTS OF SAMPLES 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 9.1 The remnants of samples are non-returnable. 9.2 The remnants of samples are to be scrapped. 9.3 The remnants of samples can be disposed off without any deshaping.

13 SECTION-IV: CERTIFICATION CRITERIA Page 4 of 4 DOC NO:PM/398-4/007 SH.P.K.GAMBHIR,Sc-G & CHIEF (CERTIFICATION) 9.4 No special care is called for in dealing with the remnants of samples PROCEDURE TO BE FOLLOWED FOR DESTROYING/ DESHAPING/ RECYCLING THE PRODUCT THAT DOES NOT MEET THE QUALITY PARAMETERS DURING REGULAR PRODUCTION 10.1 Non-conforming material shall not be stored together with that conforming to the specification to prevent accidental usage Non-conforming material shall be scrapped and disposed off as scrapped A separate record shall be maintained giving information relating to the rejection of the production not conforming to the requirements of the specification and the method of its disposal.

14 DOC: STI/398 (Pt.4)/3 July 2000 SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF ALUMINIUM ALLOY STRANDED CONDUCTORS ACCORDING TO IS 398 (Pt.4) LABORATROY: A laboratory shall be maintained which shall be suitably equipped and staffed where different tests given in the specification shall be carried out in accordance with the methods given in the specification. 1.1 All testing apparatus shall be periodically checked and calibrated and records of such checks/calibration shall be maintained. 2.0 TEST RECORDS: All records of tests and inspection shall be kept in suitable forms approved by the Bureau. 2.1 Copes of any records and other connected papers that may be required by the Bureau shall be made available at any time on request. 3.0 QUALITY CONTROL: It is recommended that, as far as possible, Statistical Quality Control (SQC) methods may be used for controlling the quality of the product during production as envisaged in this Scheme [See IS 397 (Part I) : 1972, IS 397 (Part 2) : 1985 and IS 397 (Part 3) : 1980]. 3.1 In addition, effort should be made to gradually introduce a Quality Management System in accordance with the Quality System Modules as per IS/ISO 9001 or IS/ISO 9002 or IS/ISO 9003 as appropriate to the activities of the organization. 4. STANDARD MARK: In Standard Mark (s) as given in column (1) of the first Schedule of the licence shall be marked on label attached to each coil of conductor and on each drum or reel on which conductor is coiled, provided always that the conductor to which this mark is applied conforms to every requirement of the specification. 5.0 MARKING: In addition, each drum or reel shall have the additional information marked on it as per clause 11.1 of the standard along with other essential data. 5.1 The Standard Mark shall be applied in such a manner that, as far as possible, the drums or reels to not retain the Standard Mark intact after opening up, as other wise these might be fraudulently used by any person so as to deceive that his product coiled on the drums or reels carried the Standard Mark and this conforms to the specification.

15 DOC: STI/398 (Pt.4)/3 July STANDARD LENGTH: Unless otherwise agreed to between the purchaser and the manufacturer, stranded Alluminium alloy conductors shall be supplied in the manufacturer s usual production lengths and with a permitted variation of +5 percent in the length of any one conductor length. 6.1 RANDOM LENGTH: Unless otherwise agreed to between the purchaser and the supplier, it shall be permissible to supply not more than 10 percent of the length on any one order in random lengths; none of them shall be shorter than one third of the nominal length. 7.0 LEVELS OF CONTROL: The tests as indicated in Table 1 and at the levels of control specified therein, shall be carried out on the whole production of the factory covered by this scheme and appropriate records maintained in accordance with para 2 above. All the production which conform to Indian Standard and covered by this license shall be marked with Standard Mark. 7.1 On the basis of test and inspection results, decision regarding conformity or otherwise of the lot as a whole with the requirements of the specification shall be made as follows: Each of the samples taken for tests shall satisfy the requirements of the specification for acceptance of the lot. 7.2 In respect of all other clauses of the specification and at all stages of the manufacture, the factory shall maintain appropriate control and checks to ensure that their product conforms to the various requirements of the specification. 8.0 RAW MATERIAL: The licensee shall obtain certificates from suppliers of Alluminium alloy certifying that the material supplied has composition appropriate to the mechanical and electrical properties specified in table 1 of IS 398 (Pt.4): In case the licensees procures Aluminum Alloy Wires, each drum/coil of wire shall be accompanied with a test certificate identify the heat treatment batch and indicating that the wires supplied has conforming the requirements of the mechanical and electrical properties specified in Table 1 of IS 398 (Part 4):1994. Proper records of all the all alloy wire shall be kept for the purpose of identification and traceability. 9. REJECTIONS: A separate record shall be maintained giving information relating to the rejection of the production not conforming to the requirements of the specification and the method of its disposal. Such material shall in no be stored together with that conforming to the specification.

16 DOC: STI/398 (Pt.4)/3 July SAMPLES: The licensee shall supply, free of charge, the samples required in accordance with the Bureau of Indian Standards (Certification) Regulations, 1988, as subsequently amended, from the factory or godowns. The Bureau shall pay for the samples taken by it from the open market REPLACEMENT: Whenever a complaint is received soon after the goods with Standard Marks have been purchased and used and if there is adequate evidence that the goods have not been misused, defective goods or their components are replaced or repaired free of cost by the licensee in case the complaint is proved to be genuine and the warranty period (where applicable) has not expired. The final authority to judge the conformity of the product to the Indian Standard shall be with the Bureau In the event of any damages caused by the goods bearing the Standard Mark, or claim being filed by the consumers against BIS Standard Mark and not conforming to the relevant Indian Standard, entire liability arising out of such non conforming product shall be licensee and BIS shall not be in any way be responsible in such cases STOP MARKING: The marking of the product shall be stopped under intimation to the Bureau if, at any time, there is some difficulty in maintaining the conformity of their product to the specification, or the testing equipment goes out of order. The marking may be resumed as soon as the defects are removed under intimation to Bureau. The marking of the product shall be stopped immediately if directed to do by Bureau for any reason. The marking may then be resumed only after permission by the Bureau. The information regarding resumption of markings shall also be sent to the Bureau PRODUCTION DATA: The licensee shall maintain production data as per enclosed proforma-i, which may be authenticated by a Chartered Accountant or by the licensee by giving affidavit (which may be required along with renewal application). The licensee shall sent to the Bureau as per the enclosed, proforma-2 and proforma-3 a statement of quantity produced, marked and exported by him and the trade value thereof during the half year ending 30 June and 31 December. This statement is required to be forwarded to the Bureau on or before 31 st day of July and January for the preceding half year. Table 1

17 IS 398 (Part 4): 1994 TABLE 1 LEVELS OF CONTROL (Para 6 of the Scheme of Testing and Inspection) DOC: STI/398 (Pt.4)/3 July 2000 TEST DETAILS Clause Requirements Alluminium Alloy Wire (Procured from outside source) Clause Test Method Reference LEVELS OF CONTROL No. of Frequency Samples Remarks 6. Freedom from defects 6.1 IS398(Pt.4): Every If any sample fails bobbin/coil of aluminium in respect of any 7.1 Diameter 7.1 & wire procured. requirement, two Table 1 -domore samples from the same bobbob/ coil/shall be tested 5.1 Breaking load do- for that requirement 5.1 Elongation doand if there is any further failure in 5.1 Resistance 12.4 retesting, the bobbob/coil shall be rejected. Note: In case Alluminium Alloy wires have been drawn and heat treated in house, than all the above tests shall be done on at least one drum drawn out of a lot of 10 drum (max.) which have been heat treated at the same time. If any sample fails in respect of any requirement, two more samples from the same bobbin/coil tested for that requirement and if there is only failure in retesting the bobbin/coil shall be rejected. For remaining coils of the lot each bobbin/coil shall be tested and shall be accepted only if found conforming to all the tests. STRANDING. 7.2 Sizes & -do- Table Resistance & -do- Table 2 1 Each length of stranded conductor 1 -do- 9.2 Lay Ratio 9.2 & -do- Table 3 1 -do- 8. Joint in Wires 8.1 & 8.2 -do- Each length of the conductor produced.

18 SECTION-V: INSPECTION AND TESTING Page 1 of 2 DOC NO:PM/398-4/008 SH.P.K.GAMBHIR,Sc-G & CHIEF (CERTIFICATION) 1.0 PACKING MATERIAL REQUIREMENT (TO BE AVAILABLE IN FACTORY AT ALL TIMES) FOR PACKING/ DISPATCH OF SAMPLES 1.1 The conductors are packed and despatched in large drum /reel/bobbins either made of wood or metal or other material of suitable strength. 1.2 Each drum or reel shall have the additional information on it as per clause 11.1 of the standard along with other essential data. 1.3 The Standard Mark shall be applied in such a manner that, as far as possible, the drums or reels to not retain the Standard Mark intact after opening up, as other wise these might be fraudulently used by any person so as to deceive that his product coiled on the drums or reels carried the Standard Mark and this conforms to the specification. 2.0 LIST OF REQUIRED TEST EQUIPMENT/FACILITIES WITH REQUIREMENT AND FREQUENCY OF CALIBRATION (To be provided by CL) 3.0 STATUS OF TEST FACILITIES IN BIS LABS AND OSLS WITH TESTING CHARGES, AND APPROXIMATE TIME REQUIRED FOR TESTING BY BIS LABS/OSLS (To be provided by CL) 4.0 WHETHER GRANT OF LICENCE/INCLUSION WILL BE BASED ON FT/IT 4.1 The grant of licence/inclusion can be based on either Independent testing (at BIS labs or BIS recognised Laboratories) or by Factory testing at firms premises at the discretion of the Head of the BO who takes decision based on the requests by the firm, available BIS manpower, the quantity and size of the samples to be tested. 4.2 Inspection Charges for each additional mandays should be charged at the rate of special inspection charges prevalent.

19 SECTION-V: INSPECTION AND TESTING Page 2 of 2 DOC NO:PM/398-4/008 SH.P.K.GAMBHIR,Sc-G & CHIEF (CERTIFICATION) 5.0 DETAILS OF TESTS TO BE DRAWN IN CASE OF AS/VS/FS/MS AND RAW MATERIAL SAMPLES TO BE TESTED/TESTS TO BE CARRIED IN FACTORY 5.1 No testing of rawmaterial aluminium alloy rods is necessary for any type of samples. 5.2 Applicant Samples/Verification Samples: All tests on i)the wire before stranding and ii)the stranded conductor to be carried out as per the ISS. 5.3 Surveillance/Market Samples All tests on the stranded conductor to be carried out as per the ISS The product is directly supplied to all state electricity boards and power corporations. Hence it may not be possible to obtain market samples. In such cases feedback from these organised buyers may also be obtained on the performance of the product. 5.4 Except when grant of licence/ inclusion is based on Factory Testing, testing which is possible in a day excluding the time for audit is sufficient during Factory Testing.