BUREAU OF INDIAN STANDARDS (CENTRAL MARKS DEPARTMENT-III) Our Ref: CMD-III/16:1239(Pt 1) 11 Oct 2004

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1 BUREAU OF INDIAN STANDARDS (CENTRAL MARKS DEPARTMENT-III) Our Ref: CMD-III/16:1239(Pt 1) 11 Subject: Implementation of revised IS 1239(Pt 1):2004 Steel tubes and revised STI [Doc:STI/1239(Part 1)/8 ] IS 1239(Part 1):1990 has been revised and published as IS 1239(Part 1):2004. In the revision of IS 1239(Part 1), following changes have been made: i) All the amendments on the fifth revision have been incorporated. ii) Chemical composition for seamless tubes (ladle analysis) has been incorporated and for manufacturing of welded tubes, IS Hot-rolled steel strip for welded tubes and pipes or IS 513 Cold rolled low carbon steel sheets and strips have been included. iii) Permissible variation in case of product analysis of seamless tubes for all specified elements have been incorporated. iv) Provision for supply of tubes with bevel end has been incorporated. In the title of the specification word Mild has been deleted. Consequent upon revision of IS 1239(Pt 1), STI has been revised as Doc:STI/1239 (Pt 1)/8 (copy enclosed. In the revised STI, provision of various circulars issued regarding marking on tubes have been incorporated. There is no change in the manufacturing or testing facilities as per revised STI. Therefore, no verification is required. a) It is proposed that the revised STI be implemented w.e.f. 30 Nov b) BOs to inform licensees about revised specification and STI. The revised STI be endorsed in the licence on receipt of acceptance of revised STI. c) All pending applications be processed as per IS 1239(Part 1):2004. Submitted for approval please. Encl: As above Sd/- (C.K. Veda) Director (CMD-III) Sd-/ DDGM

2 SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF STEEL TUBES ACCORDING TO IS 1239 (Pt.1):2004 (Six Revision) DOC:STI/1239(Pt.1)/8 1. LABORATORY 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. 2. TEST RECORDS - All records of tests, inspection and calibration shall be kept in suitable forms approved by the Bureau. 2.1 All testing apparatus/measuring instruments shall be periodically checked and calibrated and records of such checks/calibration shall be maintained. 2.2 Copies of any records and other connected papers that may be required by the Bureau shall be made available at any time on request. 3. 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 IS/ISO 9000 series as appropriate to the activities of the organization. 4. STANDARD MARK The Standard Mark, as given in Column (1) of the First Schedule of the licence, as applicable, shall be embossed at a suitable place on the outside of each tube provided always that the tubes so marked conform to all the requirements of the specification. 4.1 The different classes of tubes shall be distinguished by colour bands which shall be applied as per clause 17.2, 17.3 and 17.4 of the specification before the tubes leave the factory. 4.2 Each tube shall be embossed with the manufacturer s name or trade mark, IS (i.e. IS 1239) (Pt.1) and class of tubes i.e. L, M or H for Light, Medium and Heavy class as applicable at regular interval of say one metre. 4.3 Each tube of size 25 mm NB and above shall be marked with batch number by embossing/stencilling/transfix label/etching. For sizes upto and including 20 mm NB, batch number shall be marked on the tag attached to the bundle of steel tubes. NOTE : Effort should be made to mark the batch number on individual tubes upto 20 mm NB also. Based on the experience gained in marking of batch number, the marking clause would be reviewed.

3 DOC:STI/1239(Pt.1)/8 4.4 Licence number (CM/L..) shall be marked on each tube by embossing/ stencilling/transfix labels/etching. 4.5 In addition the following information shall be included in the durable tag (metal/plastic) attached to each bundle : a) The class of tubes/ process of manufacture (Cl. 6.3); b) Identity of the source of manufacture; c) Size; d) Batch number or Identification mark in code or otherwise to enable the date of manufacture and control unit no. to be traced back to factory records; e) Made in India (if required);and f) Licence number (CM/L..). 5.0 Test Certificate If so desired by the purchaser, for each consignment of BIS certified material conforming to IS 1239 (Part I):2004, test certificate may be issued which shall contain the Standard Mark, cast/control unit number, type, class, size of tubes and corresponding test results as given in Annex 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 of the factory which is covered by this scheme and appropriate records and charts maintained in accordance with paragraph 2.0 above. All the production which conforms to the Indian Standards and covered by the licence shall be marked with certification mark of the Bureau. 6.1 CONTROL UNIT - For the purpose of this scheme of Testing & Inspection, one shift production of one size & class of tubes on each tube mill shall constitute one control unit. 6.2 No manufacturer shall produce tubes of wall thickness less than the wall thickness of Light class tubes as stipulated, under the Mild Steel Tubes (Quality Control ) Order 1978 issued by the Government of India, Ministry of Industry (Department of Heavy Industry) dated 18 July SOCKET Unless specified otherwise, each screwed tube shall be supplied with one socket conforming to all requirements (except 6.4) of IS 1239(Pt.2):1992 and a thread protecting cap on the other end of the pipe. 7.1 SOCKET INSPECTION : The socket supplied with the tube shall either bear BIS Standard Mark or samples drawn from each consignment of sockets shall be tested as per Table 2 for its conformity to the standard [except 6.4 of IS 1239(Pt.2)] and shall be used when found satisfactory. Licensee shall ensure tracebility and identification of sockets. 8.0 In respect of all other clauses of the specification the factory will maintain appropriate control and checks to ensure that their product conforms to the various requirements of this specification.

4 DOC:STI/1239(Pt.1)/8 9.0 REJECTIONS A separate record shall be maintained giving information relating to the rejection of tubes and method of their disposal which do not conform to the specification. Rejected pipes shall be either punched with holes of minimum 5 mm diameter to be clear and through at an interval of maximum 1.5 mt or cut into lengths not in excess of 1.5 meters before being sold [please refer to para 4 of Mild Steel Tubes (Quality Control) Order 1978 issued by Government of India, Ministry of Industry (Department of Heavy Industry) dated 18 July 1978 as amended on 1 st Jan 1983]. Rejected tubes shall not be colour coded and Standard Mark (if already applied) should be defaced. 10 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. 110 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. A record of complaints shall be maintained as per proforma enclosed at Annexure II 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 of licensee and BIS shall not 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 so 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 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

5 DOC:STI/1239(Pt.1)/8 TEST DETAILS Cl. Requirement Test Methods 6.1.1, 6.2 & 7 Steel Skelp/Strip Chemical Composition Thickness of slitted coils IS 1239 (Pt.1):2004 STEEL TUBES TABLE 1 LEVELS OF CONTROL (Para 6 of the Scheme of Testing and Inspection) Clause Of samples Lot Size Reference IS or IS 513 or IS 228 Each cast Table IS 1239(Pt.1) 3 to 5 8 Dimensions 8.1, IS 1239(Pt.1) & (Table 3 to 5) Mass Mass (10 tonne mini mum) (Individual Pipe) Four -do- - do - -do- Each slitted coil. hour s produc tion of tubes of one particu lar size and class at each tube mill -do- -do- lot 10 tonne min LEVELS OF CONTROL Frequency Every hour Every 10 th control unit* No Testing is necessary if the consignment of steel strip is covered by ISI mark and received with manufacturers test certificate. In case of failure of sample, suspend production and investigate the cause of failure and rectify defect. 100% inspection of material produced during one hour prior to failure to segregate conforming and nonconforming tubes. Dispose of nonconforming tubes as per laid down procedure For subsequent productions, frequency of testing shall be changed to 15 minutes till 5 consecutive samples pass. * In case of failure, each pipe shall be checked for weightment as per Clause 9.1 (b), 1&2 of IS 1239(Pt.1):2004 and pipes not conforming to the specified requirement shall be rejected and scrapped as per M.S. Tube Quality Control Order After segregation lot shall be re-checked by addition of pipes manufactured subsequently to make lot of 10 tonnes minimum. Three lots manufactured subsequently shall be checked for weighment and if all found conforming to clause 9.1 (b) 3 & 4 of IS 1239 (Pt.1):2004, normal frequency may be resumed.

6 TEST DETAILS Cl. Requirement Test Methods IS 1239 (Pt.1):2004 STEEL TUBES TABLE 1 LEVELS OF CONTROL (Para 6 of the Scheme of Testing and Inspection) Of samples Lot Size Clause Reference 10.1 Joints (Tubes) 10.1 IS 1239(Pt.1) hour s producti on of tubes of one particul ar size and class at each Threadi ng m/c Sockets IS 1239(Pt.2) Ref Table 2 of STI If ISI marked sockets are used no further testing is required DOC:STI/1239(Pt.1)/8 LEVELS OF CONTROL Frequency Every hour sample of after every one hour production at each threading machine shall be taken and checked for the requirement of thread. If a sample fails, the production during the hour prior to drawl of test sample on that particular machine shall be considered as not fit to be covered. However, all production of the previous one hour may be sorted out and those found failing shall be reworked. All the pipes threaded after this failure shall be tested till five consecutive samples pass and thereafter the frequency of one sample/hour shall be resumed Tube end 10.2 & IS 1239(Pt 1) Fig Length 11.1 to IS 1239(Pt.1) Galvanizing & -do- & 12.2 IS 4736 Two (Once every four hours) hour s producti on hour s producti on shift producti on of one size & class Every hour Every hour Each control unit Records shall be maintained sample in the beginning; once every four hours. In case of failure in visual defects, segregate defective tubes and regalvanize. In case of other defects regalvanize all tubes.

7 TEST DETAILS Cl. Requirement Test Methods 13. Hydrostatic testing on black finished tubes Clause Reference 13.1 & IS 1239 (Pt.1) Body current test 13.1 & -do- Annex B 14.1 Tensile strength and elongation 14.1 & -do IS 1608 & IS Bend test 14.2 IS 1239(Pt.1) & IS 2329 DOC:STI/1239(Pt.1)/8 IS 1239 (Pt.1):2004 STEEL TUBES TABLE 1 LEVELS OF CONTROL (Para 6 of the Scheme of Testing and Inspection) Of samples Each tube -do- Two Lot Size shift (one every four hours production of tubes of one size and class at each tube mill hours production of one size & class of Tubes at each tube mill -do- LEVELS OF CONTROL Frequency Each control unit Every hour The tubes which fail shall not be marked Subject to mutual agreement between the purchaser and the manufacturer eddy current test may be done in place of hydrostatic test, Should any one of the test piece first selected fail to pass any of the test specified, two further sample shall be selected for testing in respect of each failure. Should the test pieces from both these additional sample pass, the material shall be deemed to comply with the requirements of that particular test. Should the test pieces from either of these additional sample fail, the material represented by the test samples shall be deemed as not complying with the Standard Flattening test 14.3 IS 1239(Pt.1) & IS do- 15. Workmanship 15 IS 1239 (Pt.1) Each tube The tube failing in this requirement shall not be marked 17. Marking 17 IS 1239(Pt.1) (Visual) 18 Protection & 18 -do- Packing IS 4740 Adequate Inspection to ensure each tube to be in accordanc e with the requireme nts of the specificati on. (See also Cl.4 of STI)

8 TEST DETAILS Cl. Requirement Test Methods 7 Chemical composition 8&9 Dimensions & tolerances IS 1239 (Pt.2:1992 MILD STEEL SOCKETS TABLE 2 LEVELS OF CONTROL (Para 7.1 of the Scheme of Testing and Inspection) Clause Reference Of samples Lot Size IS Each consign ment Suitable gauges And measuring Instruments 10 Joints 9 IS 1239 (Pt.2) & IS Pressure Test a) Hydraulic OR 11 IS 1239(Pt.2) b) Air pressure -do Expansion test & -do Table 1 of IS 4711 to be followed -do- Table 30 of IS 1239 (Pt.2):92 Table 2 of IS 4711 to be followed. For details and criteria of comfor mity refer IS Galvanizing IS Each consign ment 14 Workmanship Visual Each Piece DOC:STI/1239(Pt.1)/8 LEVELS OF CONTROL Frequency In case sockets are BIS certified, no testing is required.

9 DOC:STI/1239(Pt.1)/8 ANNEXURE -I (Para 5 of the Scheme of Testing and Inspection ) XYZ - IRON AND STEEL COMPANY (Registered Office Address and works address) TEST CERTIFICATE FOR STEEL TUBES ISI LOGO TEST CERTIFICATE NO. DATE To M/s We certifiy that the material described below fully conforms to IS 1239(Pt.1):2004 Chemical composition and mechanical properties of the product, as tested in accordance with the Scheme of Testing and Inspection contained in the BIS Certification Marks Licence CM/L are as indicated below against each order no. {PLEASE REFER TO IS IS 1239(Pt.1):2004 FOR DETAILS OF SPECIFICATION REQUIREMENTS} TEST RESULTS Order Date Size Clas s/ Type Cast / Lot Qua ntity Ton nes CHEMICAL ANALYSIS C % Mn % S % P % MECHANICAL PROPERTIES Tensile Strengt h MPa Elon gatio n % Flatt enin g/ Ben d Test GALVANIZING Weig ht g/m 2 Uniformi ty REMARKS It is certified that each steel tube is eddy current/hydrostatically tested to test pressure of 5 MPa. Screwed tubes and sockets are supplied with pipe threads conforming to IS 554 and material supplied conforms to standard dimensions and mass tolerances. REMARKS SHIPPING ADVICE NO. WAGON NO. TRUCK NO. SIGNATURE OF AUTHORISED SIGNATORY DESIGNATION FOR XYZ IRON AND STEEL COMPANY (It is suggested that size A-4 paper 210 X297 mm be used for this Test Certificate)

10 ANNEXURE - II COMPLAINT RECORDS Sl Date of receipt of complaint Complaint Description of Tubes Invoice & Date Quan\tity under complaint Nature of complaint Investigation Findings Action taken Quantity rejected and its disposal Corrective action taken