BUREAU OF INDIAN STANDARDS (Western Region Office, Mumbai) DRAFT PRODUCT CERTIFICATION MANUAL FOR COMMENTS. Our Ref: DDGW Sectt(PCO/RD) 23 Jan 2014

Transcription

1 (Western Region Office, Mumbai) DRAFT FOR COMMENTS Our Ref: DDGW Sectt(PCO/RD) 23 Jan 2014 Sub: Preparation & review of draft manuals for product certification This has reference to CMD circular CMD-1/31 dtd:11 Nov 2013 on the above subject. In this connection, please find enclosed the draft product certification manuals prepared by WRO as indicated in Annex-I Kindly examine the draft product certification manuals and forward your comments on the drafts to the ROs/ BO S indicated against them in Annex-I and a copy of the comments may also be forwarded to at wro@bis.org.in Last date for comments: 3 Feb Comments, if any, may please be made in the format as given below: Sl. Name Clause/ Paragraph / Type of Comments Proposed Change No. of RO / Sub-clause Figure / comment BO Table (General / Technical / Editorial) Note: Separate sheets may be attached in case comments are lengthy and cannot be incorporated in the table. (Rosy Dhawan) Sc E & PCO (DDGW Sectt)

2 Amendment Sheet

3 FORWORD This manual elaborates principle manufacturing processes, infrastructure and quality controls, Scheme of Testing and inspection,marking fee rates, guidelines for writing scope of licence and inclusion of new types, Size of sample to be drawn for testing and manner of sealing it, list of test equipments/facilities, testing charges, testing time and Test facilities at BIS labs/osls etc. This also outlines raw materials involved in manufacturing of the product. This manual aims in providing basic inputs and all essential aspects with the expectation of bringing uniformity in BIS certification activity of the product. This document is intended for internal use by BIS inspecting officers who should however do not treat such document as replacement for referred Standards or that of relevant Scheme for Testing and Inspection (STI).

4 Table of Contents SECTION I Description of Product(s) Latest Indian Standard List of Referred Indian Standards Checklist for Submission of an application for GOL SECTION II RAW MATERIALS List of Important Raw Materials SECTION III MANUFACTURING PROCESS & IN-PROCESS QUALITY CONTROLS Manufacturing Process & Control Section Infrastructure for production SECTION IV CRITERIA Identification of critical requirements of IS 8034:2002 Scheme of testing and inspection Marking fees Guidelines for writing scope of licence Guidelines for inclusion of new varieties Sample Size Manner of sealing sample Handling of Remnants SECTION IV INSPECTION AND TESTING Packing material requirement for samples List of required Test Equipment/facilities and frequency of calibration Status of Test Facilities in BIS Labs and OSLs with Testing Charges, and approximate time required for testing by BIS Labs/OSLs Basis for Grant of Licence Details of Tests to be carried out in factory SECTION V OTHER IMPORTANT ASPECTS

5 SECTION I DESCRIPTION a) Product Description: Submersible pumpsets Submersible pump sets is commanally used for drawing water from the waterbed for domestic and industrial and agricultural purposes. The standard IS 8034:2002 for submersible pump sets was first published in After the gaining of experience and expertise in manufacturing and testing, the requirements of the standard was reviewed from time to time and the better requirements were inculcated in this standard to improve the working and efficiency of the pump sets, there by the improvement in efficiency. The latest version of the standard is of The submersible pumps are of two types 1. Radial flow submersible pumps 2. Mixed flow submersible pumps The constructs part of the submersible pump essentially consists of the following: a) Pump sub assembly b) Motor sub assembly c) Coupling d) Non return valve (NRV) e) Discharge casing (If provided) either integral or separate. f) Cable and Cable guards b) LATEST INDIAN STANDARD: a. IS 8034:2002(Amendments -2) b. Submersible pump sets- Specification

6 c) List of referred standard d) CHECK LIST FOR SUBMISSION OF AN APPLICATION FOR GOL As per annexure A

7 Section II Raw Materials and components The raw material various components are given below along with the refer standards for raw materials

8 Section III Manufacturing Process and In- Process Quality Control a) Manufacturing process and in process quality control Description of manufacturing process 1) Castings are procured from approved suppliers as per drawings 2) After procurement of casting and components from the relevant parties, the pipe of required sizes are cut and stamping of required stack length as per the horse power or kilo watt are inserted in the pipe with help of hydraulic press and welding is carried on both the sided of stamping. Then the welded pipes are turned from inside and outside. Threading is carried out on both side of the pipes. 3) Rough machining is carried out on rotor and pipe bars and stampings are inserted. Copper brazing is carried out and finally, final machining along with finishing operation is carried out. 4) Balancing of rotor is done on dynamic balancing machine. 5) The distance piece is mounted after fixing the motor body on stand and rotor is attached as per the size and housing is also attached along with thrust bearing. 6) For manufacturing of the pump, the pipe sizes are cut on lathe machine and pump shaft is cut as per the size required and coupler is inserted in the pipe. 7) Complete fitting of the pump is done in following order a) Suction plate is mounted b) Fitting of bowl and impeller is carried out c) Delivery outlet is inserted in the pipe d) Pipe joined is carried out on the bowl Thus the complete pump is made ready. There after testing of the pump and the pumping set is carried out as per the IS 8034:2002. The pump which meets the requirements is given a serial number and rating plate is fixed on the pump as well as the motor.

9 Manufacturing flow chart Ferrous Parts Steel Parts Non ferrous Mis. Components Casting Parts NRV Suction Connection Piece Housing I.P.1 Machining Shaft bar cutting S.S. Pipe Cutting I.P.3 Ruff Shaft M/c S.S. Pipe M/c Stampings I.P.4 Rotor Stack I.P.5 Stator Stack Copper End ring Copper Bar Copper Wire Stud ring Thrust Bearing Oil Seal PCD Cup Bowl/Cup Bowl/ Impeller Key Sand guard Capacitor Insulating Paper Nut Bolts I.P.2 I.P.6 I.P.7 Stores I.P.8 Coil Winding Rotor stack pressing & Stator Stack Pressing Burnishing & Machining Paper Winding Rotor Machining & Balancing Pump Assy. I.P.9 I.P.11 I.P.13 Motor Assy. I.P.10 I.P.12 Dispatch I.P.14 Packing Name Plate Fitting Plating

10 b) Infrastructure for production The following manufacturing facilities/ machinery are necessary for manufacturing of submersible pump Estate, B/h Prasant foundry, Gondal road highway, Vavdi. Rajkot. Sr. No. Machinery 1 Lathe Machine 2 Lathe Machine 3 Hydraulic Press 50 4 Hydraulic Press Winding former 6 Bench Grinder 7 Drill Machine ¾ 8 Hydraulic Press 20 tone 9 Balancing Machine 10 Welding m/c 11 compressor c) In process quality control 1. Cast iron components are checked towards casting defects 2. All machine components are verified as per the drawings and sizes 3. The free running of motor is checked and assembly checks are carried out during manufacturing and assembly of pump sets 4. Continuity and high voltage tests carried out. 5. Rotor balancing is done. 6. Hydraulic testing is carried out 7. Free running of pump is checked.

11 SECTION IV Certification Criteria

12 SECTION IV Certification Criteria a) Identification of critical requirements of the Indian standard Note: To be provided by CMD b) Scheme of Testing and Inspection Enclosed as annexure B c) Marking fee rates Rs per unit with annual minimum marking fee of RS.29000/- for small scale units and Rs.34000/- for large scale units. d) Grouping guidelines 1) A series may be defined as a group of pump sets having the same Head per Stage, Discharge, Bore size, Del. Size, Category, Type of Duty, No. of Phases, Rated Voltage, No. of Poles, Type of Cooling, Any change in the above parameters will be treated as a different series. 2) The conformity of a series may be assessed by independent testing the pump set having the highest number of stages for every motor rating in a particular series. 3) The complete testing of pump sets and motors shall be carried out as per IS 8034 for every sample drawn. 4) In case, the motor for submersible pump sets are ISI Marked, even then the same shall be tested as per IS 8034 for considering inclusion GOL, since IS 8034 stipulates more stringent conditions with respects to temperature rise test. 5) In case of extension of a particular series of pump sets already covered in the licence, samples as per the above plan shall be drawn and independently tested. e) Guidelines for scope of writing While writing the scope of the writing followings points are to be kept in concentration 1) Model No is mentioned 2) Duty point values of Head- Discharge per second, overall efficiency, No. of stages, Pump bore sizes, Discharges outlet size, motor specifications (giving information regarding HP/kW, maximum current drawl, type of connection, motor efficiency, stating torque as % of ful load torque, No of phases, type of motor (wet type/ dry type), No of poles, Duty ratings, category, operating voltage, Rated frequency, (In case of single phase motor the value of starting capacitor and running capacitor to be given) head range is to be given) all this information to be provided in a table given in CMD circular CMD-III/16:8034/14220/9079/9283 Dated

13 f) Guidelines for Inclusion of new variety The Guidelines for Inclusion of new variety is to be followed as per the circular issued by CMD-III/16:8034/14220/9079/9283 Dated: g) Sampling Plan Sampling plan to be followed as as per the circular issued by CMD- III/16:8034/14220/9079/9283 Dated: h) Manner of sealing of samples As per the prevailing practice at RBO, the samples are signed by IO, then they are packed in corrugated pipe type package then sealed with sealing wax and brass seal. The code number is written on the corrugated pipe package as well as submersible pump sets. i) Remnants Since submersible pump is costly item remnants of the submersible pump sets after testing are returned to the licensee/applicant. j) Procedure to be followed for destroying/ reshaping/ recycling the Non confirming products In submersible pumps the pumps which do not meet we requirements are normally sold without BIS standard Marks.

14 SECTION V INSPECTION AND TESTING

15 SECTION V INSPECTION AND TESTING a) Packing material requirements (to be available in factory at all times) for packing/ Dispatch of samples Packing material required for packing of submersible pump set sample is pipe type packaging material used by the firm for supply of pump sets to the dealers shall serve the purpose of packing of sample sealed for dispatch to lab. Along with this packaging following material is required to be available with the firm. 1) Self adhesive stickers for making the tags to be a fixed on motor and submersible pump. 2) Brown labelling tags to be a fixed with the packaging material. 3) Sealing wax 4) Thread for tieing the sample containing package and afixing the sealing wax and seal for dispatch of sample to independent lab. b) List of test equipment facilities with requirements and frequency of calibration This detail is to be provided by CL. c) Status of Test facilities in BIS lab/ OSL Status of Test facilities in BIS lab: There is no BIS lab which is undertaking testing of submersible pump sets. Status of Test facilities in OSL lab: There are three OSL labs which are undertaking testing of submersible pump sets. They are: Sr. No. Name of lab Testing charges in INR Time taken For testing In days 1) NSIC Rajkot 4853/- 15 to 30 (Govt. lab) 2) EQDC-Gandhinagar 4494/- 30 to 45 (Govt. lab) 3) ERDA Vadodara 4412/- Minimum 30 (Pvt. Lab)

16 d) Basis of Grant of Licence The Grant of Licence in case of submersible pump is granted based on the independent test report. e) Details is tests to be carried out in the factory in case of: 1) Applicant/verification samples- Complete testing as per IS 8034:2002 is possible. 2) Surveillance/ Market samples- Complete testing as per IS 8034:2002 is possible. 3) Raw material samples to be got tested: form outside lab NABL approved lab