Subject: Preparation & Review of Product Manuals for Product Certification

Transcription

1 (Southern Regional Office) Our Ref: 60/CM 1 13 Jan 2014 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 651 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). (E. Devendar) Sc.G & DDGS HITSD Bureau of Indian Standards Southern Regional Office IV Cross Road, C.I.T. Campus Tharamani, Chennai sro@bis.org.in Phone: Fax:

2 ON GLAZED STONEWARE PIPES AND FITTINGS IS 651:2007 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 Copy No. Holder

3 AMENDMENT SHEET 0.1 AMENDMENT SHEET BUREAU OF INDIAN Page 1 of 1 DOC NO:PM/651/001 To ensure that each copy of this compiled product manual on Glazed Stoneware Pipes and Fittings IS 651:2007 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/651/ BIS has published an Indian Standard on Glazed Stoneware Pipes and Fittings (IS 651). This standard was first published in First, second, third, fourth and fifth revisions of the standards were issued in 1962, 1965, 1971, 1980 and 1992 respectively. This standard covers the requirements and tests for Glazed Stoneware Pipes and Fittings. The product is under voluntary certification. 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 Glazed Stoneware Pipes and Fittings. 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, in case of any difference in interpretation. Reference shall be made to for latest updates in related policy matters. 1.5 This Manual is to be used along with IS 651 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/651/003 SL.NO. DOCUMENT NO. TITLE 1. PM/651/001 AMENDMENT SHEET 2. PM/651/002 FOREWORD 3. PM/651/003 TABLE OF CONTENTS 4. PM/651/004 SECTION I: PRODUCT DESCRIPTION 5. PM/651/005 SECTION II: RAW MATERIALS/ COMPONENTS 6. PM/651/006 SECTION III: MANUFACTURING PROCESS AND IN- PROCESS QUALITY CONTROLS 7. PM/651/007 SECTION IV: CERTIFICATION CRITERIA 8. PM/651/008 SECTION V: INSPECTION AND TESTING

6 SECTION-I: PRODUCT DESCRIPTION Page 1 of 2 DOC NO:PM/651/ DESCRIPTION OF PRODUCT 1.1 Glazed Stoneware was known for many centuries. Glazed Stoneware Pipes and Fittings are made from clay and glazed and fired in kiln. These products are in use for more than a century and are mainly used in sewer pies and drainages due to its ability to withstand associated corrosion. The Indian Standard covers the following Glazed Stoneware or vitrified clay pipes and fittings: a) Straight and taper pipes; b) Bends; c) Taper bend: d) Junctions; e) Half-section channels, straight and taper f) Channel junctions; g) Channel bends; h) Channel interceptors; j) Gully traps; and k) Inspection pipes. It is to be noted that pipes and fittings covered in this standard are not meant for potable water applications. 1.2 IS 651 covers the range of product in two sections, viz., Section A covering dimensions of straight pipes and all such fitting which normally form part of pipe-line and which are subject to same conditions, specifications and tests as straight pipes; Section B including dimensions of fittings which are commonly used but do not form a part of the normal pipe-line. The fittings in Section B being hand-moulded articles, their conformity to dimensional specifications is not required to be so accurate as those in Section A. 2.0 Latest Indian Standard 2.1 Latest IS Secification: IS 651: Product: Glazed Stoneware Pipes and Fittings 2.3 Amendments: 1 (Amendment No. 1 June 2009)

7 SECTION-I: PRODUCT DESCRIPTION Page 2 of 2 DOC NO:PM/651/ LIST OF REFERRED FOR RAW MATERIALS AND TEST METHOD The Indian Standard does not prescribe any raw material and requirements. Hence no test methods are applicable. 4.0 LIST OF REFERRED IS Glossary of terms relating to ceramic-ware IS Dimensions for hot rolled steel, beam, column channel and angle sections IS Magnesium Sulphate (Epsom salt) IS Methods for random sampling The standards are subject to revision and applicability will be notified through policy circulars by CMD. 4.0 CHECK-LIST FOR SUBMISSION OF AN APPLICATION FOR GRANT OF LICENCE (as per Annex-B of CMD circular CMD-1/31 dt )

8 SECTION-II: RAW MATERIALS Page 1 of 1 DOC NO:PM/651/ IMPORTANT RAW MATERIALS AND CONFORMITY 1.1 The Indian Standard does not specify any raw material to manufacture Glazed Stoneware Pipes and Fittings. Also it may be noted that the products are made from clay which varies in properties from one area to another. Depending upon the source of clay additives may be or may not be required. The choice is left to the manufacturer. 1.2 The process of glazing has been stated in the standard. The glaze shall be obtained by the action of fumes of common salt on the material of pipes during the process of burning or glaze shall be ceramic glaze consisting glazing material, applied prior to firing.

9 SECTION-III: MANUFACTURIN PROCESS & IN-PROCESS QUALITY CONTROLS Page 1 of 2 DOC NO:PM/651/ DESCRIPTION OF MANUFACTURING PROCESS 1.1 A typical process flow chart in the manufacture of Glazed Stoneware Pipes and Fittings along with the in process controls are given below. It may be noted that it is a typical one giving key processes and controls. Process Process Control Points Receipt of Clay from Mines Proportioning and mixing with additives Grinding Sieving (like Vibratory Screens) Mixing with water Kneading Mill (Pug Mill) Extruder Trimming Drying Green Pipes Firing in Kiln Proportioning Time & Fineness Coarse: back to Grinding Water content Homogenity Speed Visual Visual for cracks Temperature & Duration Unloading & Cooling Sorting Sampling & Testing Visual Conformity Assessment Final Acceptance

10 SECTION-III: MANUFACTURIN PROCESS & IN-PROCESS QUALITY CONTROLS Page 2 of 2 DOC NO:PM/651/ INFRASTRUCTURE FOR PRODUCTION 2.1 The following are the minimum list of machinery needed for the manufacture of Glazed Stoneware Pipes and Fittings: 1. Batchers / Loaders for proportioning 2. Grinder 3. Sieving 4. Mixer 5. Kneader / Pugmill 6. Extruder 7. Trimmer 8. Dryer / Natural drying in yard 9. Kiln 10.Weighing machine, suitable accessories hand tools, loaders, conveyors and other

11 SECTION-IV: CERTIFICATION CRITERIA Page 1 of 3 DOC NO:PM/651/ IDENTIFICATION OF CRITICAL REQUIREMENTS OF THE INDIAN STANDARD 1.1 The following are the critical requirements of the ISS on the products: Cl 6 Glazing Cl 7.2 Hydraulic Test Cl 7.3 Absorption Test 7 Cl 7.4 Test for Acid Resistance Cl 7.5 Test for Alkali Resistance Cl 7.6 Crushing strength test Cl. 10 to 19(Section A & B) : Dimensional and other requirements including grooving. 1.2 Cl 5 General Quality may be considered as non-critical provided the product conforms in hydraulic test (Cl. 7.2) 2.0 SCHEME OF TESTING AND INSPECTION STI/651/5 March MARKING FEE RATES Minimum Marking Fee : Rs.29,000/- for SSI Rs.34,000/- for LSI Or Rs for each unit of production (whichever is higher) (Unit1 TONNE ) 4.0 GROUPING GUIDELINES 4.1 No grouping guidelines exist as of now. For the purpose of uniformity the following grouping guideline should be followed: 4.2 (Proposed) One sample of greatest diameter of the sizes intended to be covered in each of Strength Class (SP) from the following group is be drawn for considering inclusion/grant of licence for that particular group of pipes under Section A. Group 1: Internal Diameter (mm) : upto 300

12 SECTION-IV: CERTIFICATION CRITERIA Group 1: Internal Diameter (mm) : Page 2 of 3 DOC NO:PM/651/007 For fittings also above grouping sizes may be followed. For the products under Section B, each variety shall be tested as it involves hand moulding. 4.3 Firm to declare list of the products they intend to cover in the licence. IO may accordingly verify their manufacturing capability and availability of testing facilities and based on the grouping (after approval by the CA)may recommend grant of licence/inclusion. 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 scope of the licence may be granted as follows: Glazed Stoneware Pipes of Internal Diameter from.. to (including both sizes), SP../ Fittings ( Name of the fitting) from.. to (including both sizes) of size (Section A) / (Name of the variety, size) ( Section B) as as per IS 651: GUIDELINES FOR INCLUSION OF NEW VARIETIES 6.1 The procedures as mentioned at 4.2 to 4.5 may be followed.(after approval from CA) 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 product under the group 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 diameter of the varieties under Section A and each variety under Section B keeping the guidelines in mind.

13 SECTION-IV: CERTIFICATION CRITERIA Page 3 of 3 DOC NO:PM/651/ 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 Quantity : 3 numbers in each sample for all tests 7.2 The nature of testing being only for mechanical and chemical properties, the necessity to send the samples to different labs does not arise. However, if alkali and acid resistance tests are to be carried out in different lab, considering size and nature of the product, prepared specimens also may be sent. 7.3 A counter sample of the same batch and size is also to be drawn, sealed and kept in the factory. 8.0 MANNER OF SEALING OF SAMPLES 8.1 A thread may be wound around or through the sampled product, tied, tagged 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 of without any deshaping / breaking. 9.4 No special care is called for in dealing with the remnants of samples being a clay matter 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 coverage under the licence Non-conforming material shall be sorted and disposed off or sold without the Standard Mark, if the licensee finds beneficial depending on the non-conformity 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 SECTION-V: INSPECTION AND TESTING Page 1 of 2 DOC NO:PM/651/ PACKING MATERIAL REQUIREMENT (TO BE AVAILABLE IN FACTORY AT ALL TIMES) FOR PACKING/ DISPATCH OF SAMPLES The sampled product are to be packed with shock absorbing material like formed hay, fibre boards sheets, hessian for despatch. Thread for tying and tagging to be made available (Please see 4.1 also) 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. Preferably factory testing may be permitted considering nature of the product which is brittle and heavy and requires great care in transporting and possibility of complete testing in the factory (Proposed as no such permission as policy is existing) 4.2 Inspection Charges for each additional mandays should be charged at the rate of special inspection charges prevalent. 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 raw material is involved 5.2 Applicant Samples/Verification Samples: All tests on the sample can be carried out in the factory as per the ISS.

15 SECTION-V: INSPECTION AND TESTING Page 2 of 2 DOC NO:PM/651/ Surveillance/Market Samples The licence may be operated based on factory testing considering nature of the product which is brittle and heavy and requires great care in transporting; laboratories have reported breakages of the samples (Proposed as no such permission as policy is existing) Even after procuring market samples, packaging and transporting the sample becomes very difficult hence 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.