Draft Indian Standard. GENERAL REQUIREMENTS FOR THE SUPPLY OF METALLURGICAL MATERIALS AND METALS INCLUDING STEEL (Third Revision of IS 1387)

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1 Doc: MTD 4(4669) For comments only Draft Indian Standard GENERAL REQUIREMENTS FOR THE SUPPLY OF METALLURGICAL MATERIALS AND METALS INCLUDING STEEL (Third Revision of IS 1387) ICS ICS , Not to be reproduced without permission Last date for receipt of of BIS or used as STANDARD comments is 31 May 2006 FOREWORD (Formal clause will be added later on). This standard was first published in 1959 and revised in 1967 and 1993 in order to unify certain clauses covering the general requirements for the supply of metallurgical material as given in Indian Standard specifications. Since the publication of this standard, it has been a general practice to make reference to this standard in the material specifications were the provision of this standard would be applicable. This practice has considerably simplified the presentation of specifications for metals and metal products. It has also been possible for individual purchasers and inspecting authorities to establish such provisions as may suit their special needs and to use them instead of, or as supplement to, this standard. It was felt that the original title of the specification made reference only to metals and metal products and as such doubts were expressed while making reference to this standard in specifications relating to raw materials, such as refractory materials, ferro-alloys, metallurgical coke and foundry raw materials. Therefore, it was decided to change the title and scope of this standard to cover metallurgical materials including raw materials and finished products. IS 8910:78 of the standard on General Technical Delivery requirements for steel and steel products exists as a standard of identical nature specifically meant for steel and steel products. Since many of the requirements in both of the standards being common. While revising this standard to beside updating it, provisions unique and specially applicable to the supplies of steel and steel products in addition to the provisions as are existing in this standard be included on it. On publication of this revised standard, therefore, IS 8910:1978 shall be withdrawn, paving the way of single standard to guide the supplies in the metallurgical trade. For the purpose of deciding whether a particular requirement of this standard is complied with, the final value, observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with IS 2:1960 `Rules for rounding off numerical values (revised). The number of significant places retained in the founded off value should be the same as that of the specified value in this standard. 1 SCOPE 1.1 This standard covers the general requirements for the supply of metallurgical materials including raw materials for metallurgical industries and finished metal products including steel conforming to various Indian Standard specifications. If considered acceptable by the parties concerned, this standard may be used in part or full for the supply of other materials or products. 1.2 This standard does not cover all the other provisions relating to a contract which should be separately agreed between the contracting parties. 2 TERMINOLOGY For the purpose of this standard the following definitions shall apply. 1

2 Doc: MTD 4( 4669) 2.1 Supplier The party supplying the material. The supplier may or may not be the actual manufacturer of the material. The term supplier shall also cover any party with whom the supplier places order for partial compliance. 2.2 Purchaser The party purchasing the material. The term purchaser shall also cover person expressly authorized in writing by the purchaser to act on his/or her behalf for inspection of the material. 2.3 Material Specification Unless otherwise stated, this term shall have reference to the Indian Standard specification which forms the basis of the contract for the supply of material. 2.4 Inprocess Inspection and Testing Inspection and testing carried out by the manufacturer in accordance with specified or his own procedures, on the batch actually supplied to the purchaser, in line of production and /or on representative test samples thereof. 2.5 Specific Inspection and Testing for Certification Inspection and specified testing carried out on the test batch (test lot) to be supplied, in order to verify whether the material complies with the requirements of the order. 2.6 Non-specific Inspection and Testing for Certification Inspection and testing carried out by the manufacturer in accordance with own procedures on products made by the same manufacturing process but not necessarily on products actually supplied. 2.7 Continuous Inspection of Product Characteristics For specific products, following an agreement between the parties specific product inspections (in accordance with 2.5) may be replaced by extracts from the continuous product inspection carried out by the qualified department of the manufacturer s works, approved by the purchaser. The characteristics to be verified and the values of these, the frequency of the inspection and if necessary the documents of compliance shall be agreed, as also it shall be the right of the purchaser or his representative to verify such continuous inspection by appropriate means. 2.8 Statement of Compliance with the Order Document in which the supplier states that the material supplied is in compliance with the requirements of the order, without mention of any test result. 2.9 Test Report (TR) Document in which the manufacturer states that the products supplied are in compliance with the requirements of the order and in which he supplies the results of the routine work inspection test, carried out on products made by the same manufacturing process as the consignment but not, therefore, necessarily applying to the actual products supplied. 2

3 Doc: MTD 4(4669) 2.10 Test Certificate, (TC) Certificate containing the results of all the tests specified. By agreement when ordering, the inspection and testing procedures may be carried out at the discretion of the purchaser: a) by the qualified department(see Note) of the manufacturea s works(tc); b) in the presence of the purchaser or a body designated by him(tcp) The test certificate is signed in case (a) by the representative of the qualified department and in case (b) by the purchaser or the representative of the designated body as well as by the representative of qualified department of the manufacturer. In certain special cases, by agreement when ordering, the inspection and testing may be carried out outside the production works by a body independent of the purchaser and the manufacturer. In that case, the test certificate shall be signed by the representative of that body. NOTE Qualified department: A quality assurance department independent of the production department. In certain cases, this department may be subject to approval by the purchaser Material Sample A sample is a material submitted to the purchaser for testing before approval is given for production. 3 TECHNICAL DELIVERY CONDITION TO BE SPECIFIED BY THE PURCHASER 3.1 The enquiry and order shall include the particulars given in to The details of material to be supplied. Note - For steel and steel products this shall include size shape, nominal dimensions, tolerances on dimensions, mass, number of pieces, lengths. Specifically for steel products beside these further requirements may include heat treatment conditions, conditions of treating and finishing of surface, conditions of deoxidizing wherever required The materials standard and grade Inspections and testing conditions and the type of documents required for inspection and testing as given in Table Size of a test batch (test lot) (see 5.2). 3.2 Where appropriate, the enquiry and order s hall include additional information, for example that listed in to Where a material sample is required Procedures for marking, in accordance with 9 and machining, workmanship, conditioning, protection, packaging, loading, dispatching and the place of destination Methods of statistical quality control to be used (if any) The welding operation to be used Other options in the standard. 3

4 Doc: MTD 4( 4669) Any supplementary requirements not covered by the standard including past history of the material Any technical data if product standard allows for alternative or if provision for special agreement exists The information shall be conveyed either by reference to one or more standards with stipulation of any variation allowed by standards or in the absence of a standard by stipulation of the characteristics and conditions defined by common agreement. Please see note below. NOTE If in an order, reference is made to a given Indian standard, this reference shall be interpreted as being the latest edition at the date of signing the order Contents of test certificate Any deviation in above as mutually agreed between the purchaser and supplier Document containing above information is termed as TDC document. 4 MANUFACTURING PROCESS Unless otherwise specified the choice of the manufacturing processes are left to the discretion of the manufacturer. In case of steel and steel products the steel making process comprising of melting and refining the state of deoxidation (rimming, semi killed and killed). The product making processes involved, following casting of metals preceding delivery of the products, shall be indicated to the purchaser for information if this has been specified in order. Table 1 Type of Documents Required for Various Types of Inspections and Testing (Clause and 5.1) Type of Inspection and Testing Type of Document Symbol In process inspection and testing No document or statement of compliance - or test report required Non-specific Inspection and Statement of compliance or test report TR Testing Specific inspection and testing Test certificate signed by the represenat- TC for certification carried out by the ative of the qualified department of the qualified department 1) of the works manufacturer s factory Inspection and testing for Test certificate signed by the purchaser TCP certification carried out in the or the representative of the body named presence of the purchaser or of by him, as well as by qualified departa body named by him ment of manufacturer Inspection and testing for Test certificate signed by the independent TCI certification carried out by an body independent body, the tests being carried out outside the production works Continuous inspection By agreement between the interested parties - 4

5 Doc: MTD 4(4669) 1) See Note under Inspection and sampling 5.1 General The manufacturer is responsible to the purchaser with respect to the compliance of the products with the requirements of the order. The procedures shall be examined in accordance with the requirements of suitable quality control system arranged by the manufacturer and quality assurance procedures drawn up to ensure compliance with the specified requirements. Various types of quality assurance inspection and testing as agreed to between purchaser and the manufacturer may be carried out which are given in Table 1 together with the type of document. Inspection procedures shall conform to Annex A. Special conditions applicable to steel and steel products are given in Annex B. 5.2 Formation of Test Batches (Test Lots) The method of forming test batches (test lots) shall be stated in the TDC and shall be determined by the type and production procedures (see relevant material standard) 5.3 Test Samples Test samples appropriate for the type of material shall have the dimensions specified in the material standard and test pieces shall conform to the requirements of the material standard. 6 INSPECTION AND TEST METHODS When required by the specification or at the time of order determination of chemical composition, microscopic examination or mechanical tests shall be carried out in accordance with the materials standard. The relevant Indian standard test method shall be used. Other test method may be agreed upon at the time of order, where no appropriate Indian standard exists. The accuracy of the testing machines shall be in accordance with the requirements of the corresponding Indian standards. 6.1 Special conditions for steel Some special conditions exist for steel like sorting or re-treatment. Surface and internal defects repair details are as given in Annex B. 7 RETESTS Retests shall be carried out as specified in the material standard and as agreed at the time of order. 8 CHEMICAL ANALYSIS 8.1 Samples for chemical analysis if specified in the material standard, shall be obtained either from the test sample or more generally from the cast. The sample shall be sufficient to allow three determinations 8.2 Check Analysis A check analysis may be made by the purchaser on test samples or test pieces which represent each cast, batch or casting. The number of samples shall be agreed between the purchaser and manufacturer. 5

6 Doc: MTD 4( 4669) 8.3 Protection of the Sample The sample for chemical analysis should be kept in such a manner as to avoid any contamination Containers The containers should give the necessary identification marks and be sealed if necessary. 8.4 Arbitration If arbitration is necessary, the laboratory where arbitration is to be carried out should be agreed by the parties. The two containers for possible arbitrations should be sealed both by the manufacturer and by the purchaser or by their representatives. 9 MARKING 9.1 Marking on the supply shall contain the complete information as per the relevant material standard and as agreed between the supplier and purchaser. 9.2 Where product marking is required but not detailed in the order a type of marking compatible with the type of product is left to the discretion of the manufacturer. 10 COMPLAINTS AFTER DELIVERY 10.1 In the event of complaint the manufacturer shall have an opportunity to check the merit of the claim within reasonable time. The contested item should remain available for this. ANNEX A (Clause 5.1) GENERAL CONDITIONS FOR SPECIFIC INSPECTIONS AND TESTS A-1 Inspection conditions A-1.1 Places of Inspection Inspection should be carried out as per the mutual agreement between the supplier and purchaser either at manufacturer s works or at purchaser s premises or both. The selection of samples, the preparation of test pieces and the tests themselves shall be carried out in the manufacturer s works and/or at purchaser s premises as per the mutual agreement between purchaser and supplier. The word sample covers, according to the type of test carried out, the test sample or a material representative of the material delivered. Where the works of the manufacturer does not have the necessary means, the inspection shall be carried out at any other place agreed to between the supplier and purchaser preferably in the country of the manufacturer. A-1.2 Submission for Inspection and Testing The manufacturer shall arrange with the purchaser, by mutual agreement the date of submission for inspection. 6

7 Doc: MTD 4(4669) If the representative does not present himself at the agreed date, the manufacturer, in order to avoid interruption of the manufacturing cycle, may himself carry out the inspection and deliver the test certificate to the purchaser, unless expressly prohibited. A-1.3 Rights and Duties of the Inspection Representative The inspection representative shall have access during normal production hours to the places in which the materials to be inspected are manufactured and stored. He may indicate the samples to be selected in accordance with the TDC. He shall have the option of attending selection of samples, the preparation (machining and treatment) of the test pieces and carrying out the tests. The representative who visits the workshops for inspection shall respect all the safety and occupational health regulations in force in the works and shall be accompanied, wherever possible, by a representative of the manufacturer. A-1.4 Conditions of Acceptance If all the requirements of the order and this Indian Standard are fulfilled the test batch is considered to conform and is accepted by the purchaser. NOTE This does not invalidate the purchaser s right to question within an agreed time limit, the conformity of the batch to the specification. A-2 ROUNDING OFF OF TEST RESUTLS The results of the physical, mechanical, chemical tests and measurements shall be rounded off using either the rules specified in the standards on methods of test or when the value obtained contains a greater number of significant figures than for the guaranteed value, the generally accepted rules for rounding off shall apply. A-3 RECORDS Unless otherwise specified in the order, the manufacturer shall maintain records of results of all the tests required by the specification for a minimum period of 3 years. A-4 VALIDITY OF THE DEFECTIVE TEST PIECES In all cases, a new test piece may be taken from the same test sample or from another test sample belonging to the same test batch/cast and the results obtained can be substituted for those corresponding to the defective test pieces. A-5 VALIDITY OF TESTS The results of a test may be discarded due to any of the following reasons: a) Faulty mounting of the test piece or defective operation of the test machine; b) Defective casting or machining of the test piece; c) Fracture of the test piece beyond the gauge marks; d) Casting defects in the test piece, evident after fracture; and e) Faulty working of the testing machine. It should be emphasized that every test should be conducted with due care in regard to sample selection, preparation and test procedures. In any of these cases the test result should be repeated. 7

8 Doc: MTD 4( 4669) ANNEX B (Clause 5.1) SPECIAL CONDITIONS APPLICABLE TO STEEL AND STEEL PRODUCTS B-1 INSPECTION OF MECHANICAL TEST RESULTS B-1.1 Where in a standard, the mechanical characteristics are specified by thickness categories the thickness to be considered is the nominal thickness of the products at the required location for taking samples for mechanical tests. B-1.2 In the absence of any specification in the order or the product standard, the mechanical characteristics relate to the delivery condition of the products. B-1.3 For certain tests (impact tests, for instance), the interpretation of the results is based on a sequential method as follows given in B to B B A series of tests (usually 3 tests) is carried out on test pieces taken from a single sample and the results obtained shall meet the criteria specified by the product standard (arithmetic mean and; if necessary, individual values). B In the case of unsatisfactory results, too low a mean or an individual value below the minimum specified value, a second series of tests may be carried out, again on test pieces from the same sample. B The mean of the two series of tests shall comply with the specified mean value. With regard to the individual values of the second series of tests, the requirements of the product standard shall apply. If these conditions are not satisfied, the product is rejected and re-tests are carried out on the remainder of the acceptance unit (see B 2.1.2). B-2.1 Retest Where one or more tests give unsatisfactory results retests may be carried out in accordance with the following requirements for each unsatisfactory except by agreement to the contrary when ordering. The unsatisfactory results comes from an individual tests for example tensile test or bend test. B The acceptance unit is the individual product. The manufacturer may, at his discretion, retain or not. If the product is retained, two new tests of the same type as the one giving an unsatisfactory result are carried out. Both new tests shall give satisfactory results. If not, the product is rejected. B The acceptance unit is a cast or a batch. The manufacturer may, at his discretion, retain or not retain in the acceptance unit the product, from which the unsatisfactory test piece comes, except by agreement to the contrary. B If the product is withdrawn from the acceptance unit, the inspection representative once more designates, within the same acceptance unit, two other product of his choice. Two more tests of the same type are then carried out on test pieces from these two products under the same conditions as for the first tests, both new test shall give satisfactory results. B If the product is retained in the acceptance unit, the procedure is as indicated in B , but one of the new test pieces shall be taken from the product retained in the acceptance unit; both new tests shall give satisfactory results. 8

9 Doc: MTD 4(4669) B If the result of a test should deviate significantly from the specified requirements for the steel type to be supplied, so that mixed material is suspected, B and B no longer apply. In that case, a special inspection and testing procedure may be agreed between the parties. B The unsatisfactory result arises from a sequential method as defined in B 1.3 (for instance, impact test). As indicated in B the product which has not given satisfactory results is rejected. B The procedure is as indicated in B carrying out two new series of tests on two different products from the remainder of the acceptance unit, both of which shall give satisfactory results. In that case, B no longer applies, and a second series of test may not be carried out. B-3 Sorting or Re-treatment The manufacturer reserves the right to carry out sorting or re-treatment (heat treatment or mechanical treatment, for example) of the products, except by agreement to the contrary when ordering, either before or after the re-tests and to submit these products as a new acceptance unit in accordance with the provisions of A 1.2 and 2.7 without prejudice to the purchaser. The manufacturer shall state to the inspection representative the method of sorting used or the treatment applied. B-4 Surface and Internal Defects B-4.1 Surface defects not prejudicial to the proper use of the product cannot be grounds for rejection. B The order contains, if necessary, particular specifications relating to surface appearance which supplement the general or product standards depending on the intended use. B Rejection at the manufacturer s works on the grounds of surface defects is limited to the actual products displaying such defects. B The use of special techniques, either during acceptance or after delivery to detect surface defects, as well as the procedures for interpreting the results shall be agreed at the time of order. B-4.2 Repairs Surface defects may be removed provided that the remaining thickness remains within the lower dimensional tolerance limit specified in either the product standard or the order and provided that this operation is not prejudicial to the use of the products. B The purchaser or the accepting agent may permit local repairs by welding. This agreement may apply either to the whole or only to a part of the consignment. B-4.3 Internal Defects B Internal defects not prejudicial or proper use cannot be grounds for rejection. Rejection at the manufacturer s works on the grounds of internal defects is limited to the actual products displaying such defects. B The use of special techniques at the time of acceptance (radiography, ultrasonic, magnetic detection, etc) to detect internal defects as well as the number of products to be tested 9

10 Doc: MTD 4( 4669) per acceptance unit and the procedures for interpreting the results shall be agreed at the time of order. B-5 TOLERANCES ON DIMENSIONS, SHAPE AND MASS B-5.1 Tolerances on Dimensions and Shape The product may be rejected if the dimensional or shape tolerances are exceeded. Such rejection is limited to those products where the tolerances are exceeded. B-5.2 Tolerances on Theoretical Mass Generally, the product standard or a specific standard concerning dimensional tolerances lays down tolerances: a) on the theoretical mass calculated for each product and/or; b) on the theoretical mass of an entire acceptance unit or consignment. B-5.3 Tolerances on the Number of Pieces Supplied or the Tonnage Supplied Deviations, specified as an absolute value or as a relative value between the number of pieces supplied or the tonnage supplied and the number of pieces or the tonnage ordered, respectively may also be specified in the order. B-6 ROUNDING OFF RESULTS OBTAINED BY INSPECTION AND TESTING B-6.1 Mechanical and Chemical Properties The results of mechanical and chemical tests shall be rounded off in accordance with IS 2:1960. The number of significant places retained in the rounded off value should be same as that specified in the product standard. B-6.2 Dimensional Characteristics The results of determination of dimensions (length, width, thickness, rounding, etc) and shape (squaring, cambering, straightness, flatness, kinking, ovalization, etc) are not rounded. These shall comply with the specification in the standard, taking account of the permissible deviations also given in the standard. 10