3.1 The standard mark shall be applied in such a manner that it gets destroyed when the reels are opened for use, as otherwise this might be misused.

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1 Doc:STI:3626/2 June 2001 SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF LOCKED COIL WINDING ROPES ACCORDING TO IS 3626: LABORATORY - An inspection department shall be maintained which shall be suitably equipped and staffed to carry out the different tests and various inspections given in the specification. 1.1 All the testing apparatus shall be periodically checked and calibrated and records of such checks checks shall be maintained. Pressure gauges shall be calibrated at an interval of one month. 2.0 TEST RECORDS - All records of tests and inspection shall be kept in suitable forms approved by the Bureau. 2.1 Copies of any records and other connected papers that may be required by the Bureau shall be made available at any time on request. 2.2 It is recommended that, as far as possible, Statistical Quality Control (SQC) methods may be used for controlling the quality during production as envisaged in this scheme [ See. IS 397 (Part 1):1972, IS 397(Part 2):1985 and IS 397 (Part 3):1980 ]. 2.3 In addition the provision of quality system specified in IS 14003:1988 "Quality Systems - Model for the Quality Assurance in final Inspection and Test" may be complied with as far as possible. 3.0 STANDARD MARK The standard Mark, as given in Column (1) of the First Schedule of the licence shall be stamped on a metal tag attached to each reel or drum on which ropes are coiled, provided always that the wire rope coiled on the reel or drum to which this Mark is thus applied conforms to every requirement of the specification. 3.1 The standard mark shall be applied in such a manner that it gets destroyed when the reels are opened for use, as otherwise this might be misused. 3.2 The manufacturer shall furnished to the purchaser a Certificate of test with each reel of completed rope in the proforma given in Annexure -I. 4.0 OTHER MARKING - In addition, the following information shall be legibly stamped upon a metal tag securely attached, when wire ropes are supplied in coils. In case, wire ropes are supplied in reels, the information may be stenciled on both sides, of the reels or stencilled on one side of the reel & metallic tag giving the information may be attached on the other side of the reel.

2 Doc:STI:3626/2 June 2001 a) Name of the manufacturer or his recognised trade mark, if any; b) Type of construction ; c) Identification in code or otherwise, to enable the date and lot of manufacture to be traced back to the factory records ; d) Nominal diameter of ropes; e) Tensile designation of round and shapes wires; f) Length of rope; g) Order number of purchaser; h) Type of external lubricant recommended for application in service; and i) Licence number (CM/L..). 5.0 LEVELS OF CONTROL : The tests as indicated in Table 1 attached and at the levels of control specified therein, shall be carried out on the whole production covered under this scheme and appropriate records and charts maintained in accordance with paragraph 2 above. On the basis of test results decision regarding conformity or otherwise of the control unit shall be taken. All the production which conforms to the Indian Standard and covered by the licence shall be marked with Certification Mark of the Bureau. 5.1 The rope shall not be less than the length specified by the purchaser nor shall it exceed the specified length by more than 2.5%. 5.2 All ropes shall be lubricated as per cl.7.1 of the specification. 6.0 In respect of all other clauses of the specification and at all stages of manufacture, the factory shall maintain appropriate controls and checks to ensure that their production conforms to the various requirements of the specification. 7.0 The rope shall be suitably protected to avoid damage in transit and corrosion. 8.0 In view of the fact that steel wire ropes are an item involving safety, extreme care should be exercised in the selection of raw materials and during the process of manufacture. Annexure II gives the requirements of the Director General of Mines Safety in this regard which should also be satisfied. 9.0 REJECTIONS -A separate record shall be maintained giving information relating to the rejection of production not conforming to the requirements of the specification and the method of its disposal. Such material shall in no case be stored together with that conforming to the specification 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 his factory or godowns. The Bureau shall pay for the samples taken by it from the open market.

3 Doc:STI:3626/2 June REPLACEMENT - Whenever a complaint is received soon after the goods with Standards Mark have been purchased and used, and if there is adequate evidence that the goods have not been misused, defective goods are replaced 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 conformity of the product to the Indian standards shall be with the Bureau In the event of any damage caused by the goods bearing the Standard Mark, or claim being filed by the consumers against BIS Standards Mark and not "conforming to" the relevant Indian Standard, entire liability arising out of such non conforming product shall be of the licensee and BIS shall not in any way be responsible in such cases PRODUCTION DATA - The licensee shall send to BIS as per the enclosed proforma-1 to be authenticated by a Chartered Accountant or by the manufacturer by giving an affidavit/undertaking, a statement of quantity produced, marked and exported by him and the trade value thereof at the end of each operative year of the licence. Table 1...

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5 LOCKED COILD WINDING ROPES TABLE 1 LEVELS OF CONTROL (Para 5 Of Scheme of Testing and Inspection) 3626:2001 Clause. No. Test Details Requirement Test Methods Clause Reference Levels of Control No. of Samples Lot Size Frequency 5.3 Chemical Composition 5.1 IS 1835 One One heat Each heat In case a test certificate is obtained of steel wire ensuring conformity to the specification no further analysis is required. 5.5 Galvanising Test 5.5 IS 3626:2001 Two One coil Each fifth coil of 1. Only required in case of galvanised galvanized wire rope.

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7 4. Dimensions 4.1 & -do- Two Each continuous 4.2 length of finished rope 6. Mass of rope, Table 1 -do- One -do- Breaking Force Two -do- One from each end of rope. 7.1 Construction 7.1 -do- One -do- IS 3626:2001 LOCKED COILD WINDING ROPES TABLE 1 LEVELS OF CONTROL (Para 5 Of Scheme of Testing and Inspection) Clause No. Test Details Requirement Test Methods Clause Reference Levels of Control No. of Samples Lot Size Frequency 9 Individual wires before stranding

8 Round Wires a) Diameter 10.1 IS 1835 Two Each coil If a sample fails in any of the b) Tensile strength do- one -dorequirement, the particular coil shall c) Torsion Test do- one -dobe rejected for the purpose of marking d) Reverse bend test do- one -do- ISI certified ropes Shaped Wires a) Dimensions Fig. 1 IS 3626:2001 Two -do- b) Tensile Strength do- One -do- -doc) Torsion Test do- One -dod) Reverse bend test do- One -do- IS 3626:2001 LOCKED COILD WINDING ROPES TABLE 1 LEVELS OF CONTROL (Para 5 Of Scheme of Testing and Inspection)

9 Clause No. Test Details Requirement Test Methods Clause Reference Levels of Control No. of Samples Lot size Frequency 10 * Test on wires from completed wire rope Round Wires a) Diameter 10.1 IS 1835 Nine Each continuous If two or more wires fail to pass the tensile, b) Tensile test do- -doproduction of wire torsion and reverse bend tests specified, c) Torsion Test do- -do- rope retests limited to the type of test under which d) Reverse Bend test do- -dothe failure occurred, shall be carried out. Shaped Wires If under the retest, two or more wires fail in any test, the rope represented by the Sample shall be considered not to comply a) Dimension Fig. 1 IS 3626:2001 Nine with this specification. b) Tensile Test do- -doc) Torsion Test do- -do- -dod) Reverse bend test do- -do * If required by the purchaser.

10 LOCKED COILD WINDING ROPES TABLE 1 LEVELS OF CONTROL (Para 5 Of Scheme of Testing and Inspection) IS 3626:2001 Sl. No. Test Details Requirement Test Methods Clause Reference Levels of Control No. of Samples Lot Size Frequency Round Wires IS 1835:1976 Nine Each continuous If two or more wires fail to pass the a) Diameter 10.1 production of wire tensile, torsion and reverse bend b) Tensile Test do- -dorope tests specified, retests limited to the c) Torsion Test do- -dotype of test under which the failure d) Reverse bend test do- -dooccurred, shall be carried out. If Shaped Wires If under the retest, two or more wires fail in any type of test, the rope represented by the sample shall be a) Dimension Fig. 1 IS 3626:2001 Nine considered not to comply with this b) Tensile Test do- -do- -do- specification. c) Torsion Test do- -do- d) Reverse bend test do- -do

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15 A N N E X U R E - (Clause 3.2 of Scheme of Testing & Inspection) CERTIFICATE OF TEST Certificate No.. Reel/Coil No 1) Name and address of maker or supplier of rope 2) Particulars of Rope a) Diameter of rope.. b) Number of strands... c) Number of wires per strands. d) Lay e) Coating 3) Tensile strength grade a) Date of test of sample of rope. b) Breaking load of rope (Aggregate/Actual) 4) Name and address of test house making test and examination. 5) Name and designation of signatory of test house conducting the test and examination. 6) Any other details I certify that the above particulars are correct and that the wire rope conforms to IS 3626: Signature of competent person Date

16 A N N E X U R E - II 1. Raw Material i.e. Wire Rods Requirements of the Director General of Mines Safety (formerly Chief Inspector of Mines) Regarding Raw Materials and Process Control (Para 8 of the Scheme of Testing & Inspection ) 1.1 Only coils of the same heat or cast number and having the same carbon range shall be selected for making a winding rope. Provided that in the case of Flattened strand locked coil and other special construction ropes all wires symmetrically placed about the axes of the strand of a winding rope shall be made from coil of wire rod of the same heat or cast number and of the same carbon range If coils of different heat or cast number are found mixed together such coils shall not be used for making winding ropes, unless each coil is chemically tested and carbon range of steel is again stamped on a tag and fixed on the coil. 1.2 Not less than 20 percent of the coils against each heat or cast number shall be analysed on drillings taken from both ends for carbon content. These samples shall also be macro - examined to detect segregation of carbon and sulphur. If the carbon content is not as per the suppliers' certificate or if segregation is detected in the coil of a particular 'heat', then all coils drawn for winding rope from that 'heat' shall be analysed on 100 per cent basis, and only those coils which are found to conform to the declared carbon content and found free from segregation shall be used for making a winding rope. 1.3 Each coil of wire rods shall be coloured to indicate its carbon range as per colour code, and bear a metal tag giving its heat or cast number, carbon content and size. The coils of wire rod shall be stacked systemically according to their heat or cast number and carbon content. 2.0 Heat Treatment (Patenting) 2.1 Temperature in the patenting furnace shall the thermostatically controlled and be recorded at regular intervals for each charge. 2.2 Graphs shall be used to record the temperature of patenting as well as hourly speed of wire rods or wire taken through the furnace. If the hourly speed record cannot be made directly on the same graph, a separate speed record may be maintained in a register alongwith the corresponding temperature record as ascertained from the temperature graph. 2.3 The first length of each patented coil shall be tested for tensile strength and /or macro-structure.the tensile value or the photograph shall be compared against standardized reference value or charts, as the case may be. 2.4 Pyrometers shall be calibrated at least once in every six months and the calibration charts maintained for the scrutiny of Inspecting Officers. 2.5 Every patended coil shall carry a metal tag carrying its heat or cast number, carbon content and size. Each such coil selected for making winding rope shall also have the words "WINDING ROPE' stamped on it or be capable of being so distrnguished in any other approved manner.

17 3.0 Pickling 3.1 Every coil shall be properly pickled and cleaned. 4.0 Wire drawing 4.1 No wire which carries a brazed or welded joint shall be used in the making of a winding rope. Provided that such joining of rods or wires may be done, if necessary, only before the final patenting stage. 4.2 A wire rope which has a brazed or welded joint in a wire made after the final patenting of rods or wires shall not be supplied as a winding rope. 4.3 All wires to be used in the manufacture of winding ropes shall be hand picked to ensure that they have compatible tensile, torsion and reverse bend values, and are of uniform surface hardness. 4.4 Every coil of wire selected for making a winding rope shall be marked with 'WINDING ROPE' stamped on the tag (bearing other particulars, such as coil number, tensile range, and size) by a competent person after he has satisfied himself that the coils have compatible value mentioned in clause When the wires are drawn at separate works, the manufacturer shall obtain a certificate of compliance with the requirements of 4.2 above and IS 1835:1976 from the supplier of wires, and shall also carry out at his own works independent test on the samples cut from both ends of each coil to verify that the wires satisfy the requirements of IS 1835: CORE 5.1 Each coil of the core shall be weighed just before the closing operation to check if it is fully impregnated with the lubricant. It is recommended that in no case the amount of lubricant in the core should be less than 18 per cent by weight. 5.2 The temperature of lubricant in the impregnation tank shall be thermostatiscally maintained at C. 5.3 Where pre-lubricated core is used, care shall be taken before use in the winding rope that it is free from moisture, and if necessary, the core shall be re-lubricated to satisfy the requirements of 5.1 to TYPE OF LUBRICANT 6.1 All lubricants used in the manufacture of winding rope shall be miscible. The lubricants used shall be selected in consultation with reputed lubricant manufacturers to meet the service requirements of the winding shafts. NOTE : To meet the service requirements in winding shafts, the lubricant, should be water repellant, acid free, and have close affinity to the steel used. Unless otherwise specified by the purchaser, the lubricant should also be capable of standing a temperature range of 0 0 C to 95 0 C (32 0 F to F), that is to say it should not drain out in service leaving the core or rope dry. 6.2 The lubricants used in the manufacture of winding rope shall be checked for their required properties laid down in clause 8.1 of IS 6594:1977. A record of the results of such checks shall be maintained. 6.3 The manufacturer shall advise the user about the type of lubricant that should be applied by him to the rope while in service. The type of lubricant recommended (in consultation with reputed lubricant manufacturers) shall be suitable for the working conditions in the shaft. NOTE - Generally speaking, the recommended lubricant should be acid free; it should not harden so that it will crack, chip, or peel off in a cold weather nor soften and drip in hot weather, that is to say, unless otherwise specified by the purchaser, it should be capable of with standing a temperature range of 0 0 C to 95 0 C. The lubricant should not dry out rapidly in service, but should be sufficiently adhesive and cohesive so that it will not be thrown off by vibration and high speed;

18 nor should it come off the rope and build up in the grooves of the sheaves. The lubricant should also be water repellant. 7.0 Additionnal Treatment 7.1 Wire shall be lubricated immediately before the stranding etc. 7.2 The core shall be throughly lubricanted again at the closing mochine. 7.3 A rust preventing wire rope dressing compund shall be applied on the rope either during closing operation or immediately before the rope is coiled on a reel. 8.0 Length of Lay 8.1 The length of lay, that is the pitch of winding rope shall be between seven and eight times the diameter of the rope. 9.0 Quality Control 9.1 A continuous check on the quality of the winding ropes manufactured in the works shall be maintained as follows : a) During stranding and closing operation, it shall be ensured, that size, lays, wire tension, stranding tension, strand tension, lubrication, die pressure etc. are rightly controlled. b) Surprise checks shall be carried out by test house staff to verify compliance with these requirement. They shall countersign the relevant records during every such checks. c) Special attention is invided to strict compliance with the manner of carrying out various tests specified in the relevant IS specification 9.2 The officer Incharge of Testing and Inspection Department shall be directly responsible to the head of the work, and be independent of the production Deptt. 9.3 The officer Incharge of the Test House shall be a qualified metallurgist or a qualified graduate engineer competent in metallurgy and he shall be assisted by competent staff in the Test House. 9.4 Adequate number of competent staff shall be appointed for floor inspection Service Facilities 10.1 The manufacture shall appoint a competent service engineer who shall be present at the time of installation of the rope, as far as possible, regularly visit the mines where indigenous ropes are installed, keep a check on the condition of the winding rope, and generally advise the mine management on proper maintenance and installation of the winding rope. He shall bring to the notice of the management and the Director General of Mines Safety any defects noticed by him in the winding rope at any time.