BUREAU OF INDIAN STANDARDS CENTRAL MARKS DEPARTMENT-III

Transcription

1 BUREAU OF INDIAN STANDARDS CENTRAL MARKS DEPARTMENT-III Our Ref: CMD-III/16: January 2006 Subject: Implementation of Amendment No 1 to IS 814:2004 for Covered Electrodes For Manual Metal Arc Welding of Carbon and Carbon Manganese Steel Amendment No.1 October 2005 to IS 814: 2004 has been published (copy enclosed). In view of the decisions taken during the all India review meeting of Welding Electrodes, held on 23 April 2005 at Indore and Amendment No.1 October 2005 to IS 814: 2004, the STI has been modified as Doc: STI/814/8 Feb 2006 for implementation with immediate effect Encl: As above. (S.K. Bhatia) Sc.F & Head (CMD-III) DDGM All ROs/BOs c.c. CMD-1 MTD for arranging gazette notification

2 SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF COVERED ELECTRODES FOR MANUAL METAL ARC WELDING OF CARBON AND CARBON MANGANESE STEEL ACCORDING TO IS 814:2004 (SIXTH REVISION) (In corporating Amendment No. 1, Oct 2005) DOC:STI /814/8 Feb 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. Frequency for calibration of Tensile Testing machine shall be once in a year and Impact testing machine once in two years. 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)::2003, IS 397(Part 2):2003 and IS 397(Part 3):2003]. 3.1 In addition, effort should be made to gradually introduce a Quality Management System in accordance with IS/ISO 9001: STANDARD MARK The Standard Mark, as given in Column (1) of the First Schedule of the licence, shall be printed on the body of the container and on any other packaging unit. provided always that the electrodes so marked conforms to every requirement of the specification. Where paper packing cases or wrappers are used, the Standard Mark shall be applied in such a manner that it cannot be misused. 4.1 OTHER MARKING - In addition the bundle or carton of electrodes shall be clearly marked with the following information. i) Classification as per clause 5 of IS 814:2004 ii) Manufacturer s name or recognized trade mark, if any; iii) Trade name and brief description of the electrodes iv) Size and quantity of electrodes; v) Batch No; vi) Recommended current range; polarity and open circuit voltage. vii) Recommendations for special storage conditions and redrying temperature

3 viii) Date of manufacture; ix) A cautionary note on safety during welding; x) Made in India, if required; and xi) Licence number (CM/L..). Note 1 : As agreed to between the manufacturer and the purchaser, brand name/classification shall be printed on all the electrodes. Note 2 : If the licensee wanted to mention any other information which is not related to IS specification, should preferably use separate label or demarcation for the same. DOC:STI /814/8 Feb 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 Standard and covered by the licence shall be marked with certification mark of the Bureau. 5.1 BATCH : For the purpose of this scheme a batch is defined as a lot of covered electrodes manufactured in a day on each extruder of one size, classification produced from coating identified by a dry mix or more than one dry mix of controlled chemical composition and core wire identified by a heat number or more than one heat number of controlled chemical composition (Refer Note 2 under Cl. 8.5 of IS 814:2004). 5.2 TEST PAD : Weld pad for checking electrode properties shall be prepared as recommended in Annex-F, G & H of IS 814: INITIAL TESTS - The initial tests shall be carried out once in a year on each type (classification) of electrodes manufactured during one operative year Whenever there is a change in basic material or production condition, the initial tests shall be carried out before the production is marked. 5.4 PERIODIC CHECK TESTS The periodic check test shall be carried out once in a month on each type (classification) of electrodes manufactured during the month. When the production of a type of electrodes after stoppage of production for more than six months is restarted, the periodic check test shall be conducted. The electrodes manufactured thereof shall be dispatched only after conformity of test results. 5.5 In case any size of electrodes fails to satisfy periodic check test, two further test specimens shall be prepared using electrodes drawn from the counter samples (electrodes from the same batch). If any samples fail in any of the retests, the marking of that size of electrodes shall be suspended. Causes of failure shall be investigated and necessary corrective measures shall be undertaken. Fresh samples from the products manufactured thereafter shall be tested for initial test and if the samples meet the requirements of the specification the marking may be resumed.

4 5.6 QUALITY CONTROL TESTS - Weld deposit from each batch of electrodes shall be analyzed for chemical composition and the results obtained shall be within the manufacturers acceptance limit. (Ref. Note 3 C under clause 8.5 of IS 814:2004) The manufacturer shall declare the range of chemical composition of weld metal for each classification and brand of electrodes. 5.7 RAW MATERIAL TESTS - Routine analysis of each consignment of raw materials received in the factory shall be carried out and appropriate records maintained IN PROCESS CONTROL - 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. 5.8 PACKING AND STORAGE - Electrodes shall be packed and stored as per clause 11 of IS 814:2004. DOC:STI /814/8 Feb REJECTIONS 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. Such material shall in no circumstances be stored together with that conforming to the specification. 7.0 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. 8.0 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. The firm shall have own complaint investigation system as per IS 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.

5 9.0 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 9.1 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 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 DOC:STI/814/8 February 2006 IS 814:2004 COVERED ELECTRODES FOR MANUAL METAL ARC WELDING OF CARBON AND CARBON MANAGANESE STEEL TABLE 1 LEVELS OF CONTROL (Para 5 of the Scheme of Testing and Inspection) Cl. TEST DETAILS Requireme Test Methods nt Clause Reference No. of samples LEVELS OF CONTROL Lot Size Remarks

6 6. Core Wire for electrodes Parent metal for test pieces 3. Coating ingredients 6 IS 814 One One sample from each cast or every 20 coils whichever is less IS 814 One Each consignment -do- As per company standard If the material is covered under BIS Certification Scheme, no further testing is required. One -do- In case accompanied with manufacturer s test certificate, no further testing is required. 7. Dimensions a) Diameter 7.1 IS 814 One Every half an hour Maximum, minimum diameter of each coil of the Wire should be recorded. b) Length 7.1 -do- One Every half an hour. Minimum and maximum length shall be recorded. c) Bare length of electrodes d) Concentricit y of flux covering with core wire 5.2 Coating ratio & do- One Every hour sample of each type & size 7.3 -do- -do- Every half an hour do- Annex B -do- -do- -do-

7 DOC:STI/814/8 February 2006 IS 814:2004 COVERED ELECTRODES FOR MANUAL METAL ARC WELDING OF CARBON AND CARBON MANAGANESE STEEL TABLE 1 LEVELS OF CONTROL (Para 5 of the Scheme of Testing and Inspection) TEST DETAILS Cl. Requiremen Test Methods No. t of samples Clause Reference 8.3 Initial Tests 8.3 IS 814 a) All weld 9.1 -do- One sample metal from each mechanical type tests for tensile and Impact b) Butt weld 9.2 -dobend tests c) Running 9.3 -doperformance test d) Increased 9.4 -dometal recovery tests (for electrodes claiming recovery 110% and above) e) Diffusible 9.5 -dohydrogen estimation test (for hydrogen controlled electrodes) LEVELS OF CONTROL Lot Size Remarks Once in a year. (Please refer cl. 5.3 of the Scheme)

8 f) Radiographic quality test (for radiographic quality electrodes) 7. Periodic check test a) All weld metal mechanical tests for tensile and impact b) Running Performance test 8.5 Quality control test 9.6 -do do do- One sample from each type 9.3 -do- -do- -do do- One batch of electrodes Once in a month Each batch (Please refer cl. 5.4 of the Scheme) (Please refer cl.5.6 of the Scheme) DOC:STI/814/8 February 2006 IS 814:2004 COVERED ELECTRODES FOR MANUAL METAL ARC WELDING OF CARBON AND CARBON MANAGANESE STEEL TABLE 1 LEVELS OF CONTROL (Para 5 of the Scheme of Testing and Inspection) Cl. TEST DETAILS Requireme Test Methods nt Clause Reference No. of samples LEVELS OF CONTROL Lot Size Remarks

9 8.6 Additional tests 8.6 IS 814 Subject to agreement with the manufacturer, the purchaser may request for additional tests to be made or certification to be provided for each batch of electrodes supplied. If so, the tests and batch definition shall be agreed between the purchaser and the manufacturer. 11. Packing and storage 11 -do- One carton of each size 13. Marking 13 -do- -do- Each carton Once in a shift (Please refer cl. 4 of the Scheme)

10 PERFORMA - 1 PROFORMA FOR OBTAINING PRODUCTION DETAILS Period covered Name of Licensee CM/L No. Name of Articles (s) Grade/Type/Size/Variety/Class/Rating IS No. 1.1 Brand/Trade/Name(s) of BIS Certification Marked Products 2.0 Total production of the articles(s) licensed for certification marking 2.1 Total production of the article(s) conforming to Indian Standard 3.0 Production covered with BIS Certification Mark and its value a) Quantity b) Value (Rs.) 3.1 Brand Name used on production covered under BIS Certification Mark 3.2 Calculation of marking fee on unit-rate basis; Marking Fee per unit a) Unit b) Quantity covered with BIS Certification Mark c) Marking fee rounded off in whole rupees as obtained by applying unit rates given in (a) on quantity given in (b)

11 Note : Incase a clause is not applicable, suitable remarks may be given against it. 4.0 Quantity not covered with BIS Certification Mark. If any, and the reasons for such non-coverage 4.1 Brand Name under with non certified goods were sold 5.0 Quantity Exported with BIS Standard Mark and its value 5.1 Brand Name under which BIS Certified goods are exported 6.0 Authentication by Chartered Accountant or by the manufacturer by giving an affidavit/undertaking