DRAFT PRODUCT CERTIFICATION MANUAL FOR COMMENTS COVERED ELECTRODES FOR MANUAL METAL ARC WELDING OF CARBON AND CARBON MANGANESE STEEL AS PER IS 814

Transcription

1 DRAFT PRODUCT CERTIFICATION MANUAL FOR COMMENTS Our Ref.CRO 22 / BPBO 19 Dec 2013 Please find enclosed the following draft certification manual: COVERED ELECTRODES FOR MANUAL METAL ARC WELDING OF CARBON AND CARBON MANGANESE STEEL AS PER IS 814 Kindly examine the draft product certification manual and forward your comments on the draft manuals. Last date for comments: 30 Dec Comments, if any, may please be made in the format as given below and mailed to BPBO (Bhopal) at the following id: hbplbo.bis Sl. No. Name of RO / BO Clause/ Sub clause Paragraph / Figure / Table Type of comment (General / Technical / Editorial) Comments Proposed Change Note: Separate sheets may be attached incase comments are lengthy and cannot be incorporated in the Page 1

2 DRAFT MANUAL FOR CERTIFICATION OF COVERED ELECTRODES FOR MANUAL METAL ARC WELDING OF CARBON AND CARBON MANGANESE STEEL AS PER IS 814 (FIRST ISSUE) BUREAU OF INDIAN STANDARDS MANAK BHAWAN, 9, BAHADUR SHAH ZAFAR MARG, NEW DELHI Page 2

3 Amendment Sheet S.No. Amendment No Reference no Date of Issue Date of implementation Page 3

4 FOREWORD The present manual attempts in highlighting various requirements and providing handy and significant information related to Covered Electrodes for Manual Metal Arc Welding of Carbon and Carbon Manganese Steel. It elaborates principle raw materials, manufacturing processes and desired controls, involved inspection and testing as need be practiced by BIS licencees and further monitoring thereof expected to be exercised by BIS Inspecting Officials during planned visits to those units and monitoring of BIS Certification Marks activities. Different tests as contained in relevant standards and referred standards thereof need be carried out at the licensee s laboratory by the visiting officer with knowledge and background possessed by the individual. Since such inspecting officers come from different educational and technical background and may not be experienced or even having basic knowledge in the relevant field or product category, such documentation of sectoral manual aims in providing basic inputs and all essential aspects with the expectation of bringing uniformity of vision and enabling adoption of rational practices by concerned BIS officials during their visits for inspections to such sector as well as follow up actions. Page 4

5 TABLE OF CONTENTS Section No/ Title Page no Para No 0 Amendment Sheet 2 0 Foreword 3 Section 1.0 Product Description 6-8 Para 1.1. Latest Indian Standard Number with Product Title and 6 Number of Amendments Para 1.2 List of referred Indian Standards 6 Para 1.3 Check-list for submission of an application for grant 8 of licence Section 2.0 Raw materials/ Components 9 Section 3.0 Manufacturing Process and In- Process Quality 10 Controls Para 3.1 Manufacturing Process 10 Para 3.2 Infrastructure for production 10 Section 4.0 Certification criteria Para 4.1 Identification of Critical Requirements of the Indian 11 Standard Para 4.2 Scheme of Testing and Inspection 11 Para 4.3 Marking fee Rates 11 Para 4.4 Grouping guidelines 11 Para 4.5 Guidelines for writing Scope of Licence 11 Para 4.6 Guidelines for inclusion of new varieties 11 Para 4.7 Sample size required to be sent to independent lab for 11 testing Para 4.8 Manner of sealing of samples 12 Para 4.9 Procedure of disposal of remnants of Tested Samples 12 Para 4.10 Procedure to be followed if sample does not meet the 12 specified norm as per Indian Standard during regular production Section 5.0 Inspection and Testing Para 5.1 Packing Material for packing/dispatch of samples 13 Para 5.2 List of test equipment/ Facilities with requirement and 13 frequency of Calibration Para 5.3 Status of Test Facilities in BIS labs/osls 13 Para 5.4 Grant of Licence 13 Para 5.5 Details of tests to be carried out in the factory 13 Page 5

6 Appendix-A Check list for submission of an Application for Grant of Licence Appendix-B Flow Chart Appendix-C List of Manufacturing Machinery Appendix-D Scheme of Testing and Inspection Page 6

7 SECTION I 1.0. Description of product: Manual Metal Arc Welding or Shielded Metal Arc Welding (SMAW) is a process of melting and joining of metals with an arc between a coated metal electrode and the workpiece. Because of the versatility of the process and the simplicity of its equipment and operation, manual metal arc welding is one of the world's most popular welding processes. In Manual Metal Arc Welding an electrode is used to conduct current through a work piece to fuse two pieces together and it is made of a material that is compatible with the base material being welded and is covered with a flux that gives off vapors that serve as a shielding gas and provide a layer of slag, both of which protect the weld area from atmospheric contamination Latest Indian Standard Number with Product Title and Number of Amendments: Latest Standard: IS 814:2004 Title: Covered Electrodes For Manual Metal Arc Welding of Carbon and Carbon Manganese Steel No. of Amendments: List of referred Indian Standards for raw materials/ components and test methods: The following standards contain provisions which through reference in this text, constitute provisions of this standard. At the time of publication, the editions indicated were valid. All standards are subject to revision and parties to agreements based on this standard are encouraged to investigate the possibility Of applying the most recent editions of the standards indicated below: IS No. Title 812:1957 Glossary of terms relating to welding and cutting of metals 1182: 1983 Recommended practice for radiographic examination of fusion welded butt joints in steel plates (.second revision) Page 7

8 1387: 1993 General requirements for the supply of metallurgical materials (second revision) 1395: 1982 Low and medium alloy steel covered electrodes for manual metal arc welding (third revision) 1599: 1985 Method for bend test (second revision) 1608: 1995 Mechanical testing of metals - Tensile testing (second revision) 1757: 1988 Method for charpy impact test (V-notch) for metallic materials (second revision) 1977: 1996 Low tensile structural steel (third revision) 2002: 1992 Steel Plates for pressure vessels for intermediate and high temperature service including Boilers (Second Revision) 2062: 2011 Steel for general structural purposes (fifth revision) 2879: 1998 Mild steel for metal arc welding electrodes (third revision) 3039: 1988 Structural steel for construction of hulls of ship (second revision) 8500: 1991 Structural steel-micro-alloyed (medium and high strength qualities) - Specification (fifth revision) 11802: 1986 Method for determination of diffusible hydrogen content of deposited weld metal from covered electrodes in welding mild and low alloy steels 13043: 1991 Covered manual metal arc welding electrodes - Determination of efficiency, metal recovery and Deposition coefficient 13851: 1993 Storage and redrying of covered electrodes before use Recommendations Page 8

9 1.3 Check-list for submission of an application for grant of licence: Please see Appendix-A Page 9

10 SECTION II 2.0 List of Major Raw Materials: A) Carbon steel or Carbon manganese steel Core wire for electrodes conforming to IS 2879, B) Ferro manganese, C) Iron oxides, D) Cellulose, E) Titanium oxide, F) Calcium Carbonate, G) Fluorspar. H) Silicates (Binders) Page 10

11 SECTION III 3.0 Manufacturing Process and In-process Quality Controls: 3.1 Manufacturing Process: A generalized flow chart with process controls points given at Appendix-B 3.2 Infrastructure for production: Please see Appendix-C Page 11

12 SECTION IV 4.0 Certification Criteria 4.1 Identification of Critical Requirements of the Indian Standard: (To be provided by a committee comprising the concerned officer from CMD, Member- Secretary of the concerned technical committee and an officer from central laboratory) 4.2 Scheme of Testing and Inspection: DOC: STI/814/7 December 2004 (Please see Appendix-D) 4.3. Marking fee Rates: Manufacturing Minimum Unit Slab 1 rate Slab 2 rate Status of marking Industry fee per year Large Scale Rs. 67,200/ pieces Rs.1.80/- for Rs.0.90/- for units rest of the units Small Scale Rs. 51,200/ pieces Rs.1.80/- for Rs.0.90/- for units rest of the units 4.4 Grouping guidelines: There is no grouping guidelines exists as on date to consider Grant of license/inclusion of new varieties for this product Guidelines for writing Scope of Licence: Scope of the license shall contain, Classification (coding of the electrode as per Cl 5 including type of covering), Diameter and length of the electrode. 4.6 Guidelines for inclusion of new varieties: There is no grouping guidelines exists as on date to consider Grant of license/inclusion of new varieties for this product. For getting a new classification/size included in the existing licence, a licensee is required to get the sample of each classification/size tested from BIS recognized laboratories. In case. Additional manufacturing and testing facilities are required to be declared for inclusion in the scope of the licence. 4.7 Sample size required to be sent to independent lab for testing: For Mechanical testing 50 pieces of electrodes (with weld pads) and for chemical testing 50 gm. drilling of weld metal is required. Page 12

13 It shall be ensured that the size of the sample is adequate for testing (and retesting wherever needed) the requirements for which it is desired to be tested. The technical auditor shall anticipate all requirements of the laboratory on the basis of' the relevant Indian Standards and STI, and draw the required size of the sample. Counter samples of identical size shall be drawn and left with the applicant / licensee. 4.8 Manner of sealing: Sealing - The samples are properly sealed with official seal, so that no substitution or tampering with the contents is possible subsequently. For the purpose of sealing, the technical auditor should always carry the brass seal Packing - The technical auditor shall take every precaution to ensure that the sealed samples are packed firmly in a durable packing material like carton box to withstand hazards during handling and transportation. The packed electrodes should be covered with polyethylene film tightly (to avoid samples contact with air/water). Wherever feasible, all original markings indicating the origin of the product would be removed / defaced from the sample with the objective of concealing the identity of the origin from the testing laboratory Labelling - The sample shall be labeled to indicate (a) Covered Electrodes For Manual Metal Arc Welding Of Carbon And Carbon Manganese Steel; (b) the relevant Indian Standard with its year (IS814:2004);(c) classification of the electrode; (d) quantity of sample(50 no s + 50 gms); (e) batch No./Control Unit No./date of production; (f) Sample code. Labels shall be tagged on the Packing. 4.9 Procedure of disposal of remnants of Tested Samples: These remnant samples are non returnable and shall be disposed off Procedure to be followed if sample does not meet the specified norm as per Indian Standard during regular production: In case of sample does not meet the requirements specified in Indian standard, such control unit i.e. Batch/lot shall not be marked. Those rejected batches/lots shall be scrapped. Page 13

14 SECTION V 5.0 Inspection and Testing 5.1 Packing Material: The following material should always be available with the firm for packing, sealing and dispatch of samples: Card board box or Carton box, Wax coated plain envelops, Polyethylene pouches, Polyethylene covers, Thread, Sealing wax, Candle, Match box, Gum, Stapler, Sealing tape, etc. 5.2 List of test equipment/ Facilities with requirement and frequency of Calibration: (To be prepared / provided by Central Laboratory) 5.3 Status of Test Facilities in BIS labs/osls: Technical auditor shall ensure status of laboratory and availability of testing facilities at the time of visit from BIS intranet Testing Charges: (To be provided by Central Laboratory) Approximate time required for testing by BIS labs/osls: (To be provided by Central Laboratory) 5.4 Grant of Licence: Grant of licence would be on the basis on independent testing. 5.5 Details of tests to be carried out in the factory: In case of Applicant/Verification samples: a) Core Wire for electrodes (Clause 6) b) Parent metal used for test pieces (Clause 8.1.3) c) Dimensions (Clause 7) d) Coating ratio (Clause 4.3) e) Chemical analysis (Clause 8.2) f) Initial Tests (Clause 8.3) In case of Surveillance samples: Technical auditor shall conduct maximum possible tests in order to bring out any deficiencies in test equipment/testing procedures and testing personnel as well as for spot establishment of quality of product Page 14

15 5.5.3 In case of Market samples: The laboratory shall conduct maximum possible tests in order to asses quality of the product : In case of Raw Material: Core wire of the electrode sample shall conform to IS 2879:1998 Page 15

16 APPENDIX-A CHECK-LIST FOR APPLICATION TO BE SUBMITTED BY APPLICANT TO BIS WHILE APPLYING FOR BIS LICENCE UNDER PRODUCT CERTIFICATION SCHEME OF BIS The following check-list is required to be submitted with all the applications for grant of BIS licence under the Product Certification Scheme of BIS. Please tick ( ) in the relevant box. Whether applied under: Simplified Procedure Normal Procedure Note: Refer BIS website or details of Simplified Procedure and Normal Procedure for grant of licence. No. Check-point Requirement Observations Page No. General Is the application form completely filled? Name & Address Status of Applicant (Manufacturin g Unit) IS No. & Varieties History Is the name and address of applicant (manufacturing unit applying for licence) same in the application as given in the attached document of Central/State Government a. Has it been indicated whether the applicant is a large scale or small scale unit? b. In case the applicant is a small scale unit, does the applicant hold valid Registration Certificate from the Local / State authority or from a Chartered Accountant, and is the certificate attached. c. Has it been indicated whether the applicant is a Public Sector or a Private Sector company? a. Has applicant recorded the applicable Indian Standard with correct title of the Standard? b. Where applicable, has applicant mentioned designation, grade, type, variety, size, etc., of the product for which the BIS licence is sought? a. Where applicable, has the applicant provided information regarding earlier BIS licence(s) held by them and / or cancelled in the past? b. Where applicable, has the applicant provided information regarding BIS licences currently Page 16

17 held by them? Signature Machinery Test Equipment & Calibration a. Is the application signed by the CEO of the applicant? b. In case the application is signed by a person other than the CEO, is the application signed by the authorized signatory of the applicant and his authorization is attached by the authorized signatory? a. Does applicant possess requisite manufacturing infrastructure to manufacture the product as per the Indian Standard? b. Is installed capacity of production indicated in the application? c. Does applicant have all machineries installed as per manufacturing process at the applicant s manufacturing premises? d. If answer to c above is no, does the applicant outsource any of its manufacturing processes and possesses valid agreement(s) with other manufacturing units for the outsourced processes and traceability of material, thus produced, etc.? e. If answer to d above is yes, does the applicant has any control over such outsourced activity? Are these outsourced process will ensure testing the quality of final product for all requirements at the applicant's manufacturing premises? a. Does applicant possesses requisite test facilities in-house as per the relevant Indian Standard at its factory address? b. Are valid calibration certificates for relevant test equipment attached are complete and valid at least 3 months after the date of recording? c. If reply to a above is no, does applicant have arrangement with a BIS recognized outside lab for testing of the requirements for which it does not possess test facilities in-house? Is the consent letter as attached by applicant in this regard in order? Page 17

18 Note: Relaxation in in-house test facilities may be allowed on submission of proper justification for requirements which are obligatory to get tested and for which frequency of testing, as prescribed in the relevant scheme of testing and inspection (STI),is, normally, one month or more. QC personnel Does the applicant employ qualified & experienced Quality Control (QC) personnel on permanent basis and possess documentary evidence to establish the same? Are the copies of the qualification certificates and appointment letters of the QC personnel are in order Raw Materials and Components Plant Layout Test Report(s) Where ever requirements for raw materials/ components used in the manufacturing of the product are specified in the standard, do test reports/suppliers test certificates, as submitted by the applicant show that these requirements are met as per the standard? Does copy of the plant (applicant manufacturing premises) layout clearly indicates locations of manufacturing machinery, laboratory, office, workshop, amenities, storage area, etc.? a. Is the attached test report of in-house or from independent laboratory cover all requirements of the Indian Standard and is passing in such requirements? b. In case the application is filed under simplified Procedure is the test report(s), in original, as submitted a) from BIS or its recognized laboratories? b) the test report is not older than one month from the date of submission of application, c) covers all the requirements of the standard, and d) passes in all such requirements. Undertaking In case application is under simplified procedure, an undertaking shall be obtained from the applicant on his letter-head that the licence if granted against his application shall be put under Stop Marking by BIS if the Page 18

19 Application Fee verification sample(s) (any sample including the long duration test samples) drawn during visit of the BIS officer prior to grant of licence fail to conform to the requirements of relevant Indian Standards. The licensee shall take necessary corrective actions and inform the same to BIS along with fresh samples (of rating/size/variety which facilitates verification of corrective actions on the reported failures) manufactured after taking the corrective actions. The resumption of marking in such cases shall be allowed only on the basis of independent satisfactory Test Reports of the fresh samples offered (including long duration tests where failures were in long duration tests). In case the fresh sample drawn by BIS for independent testing fails, or the licensee does not inform corrective actions taken and does not offer improved samples within 1 month of the date of Stop Marking, the licence shall be processed for cancellation and no further chance would be given to the licensee Has applicant paid requisite application fee of Rs. 1000/-, in equivalent US$ (Rs. 1000/- plus 12.36% tax for applicants from SAARC countries)? Signature Is the application countersigned by the applicant s Authorized Indian Representative? Nomination a. Has Nomination Form of authorized Indian representative (AIR) in the prescribed format on the firm s letter-head, duly signed by the authorized signatory of the applicant and the AIR or the authorized person of the company of the AIR, been submitted with the application? b. Is the authorization to the signing authority to sign the Nomination Form on behalf of the Indian Co. also submitted? c. Is address of the AIR in the Nomination Form complete and evidence of nationality, address proof, contact details like phone / fax numbers and address of the AIR submitted? Page 19

20 Language Preliminary Inspection / Visit Charges Translation Facility Agreement Indemnity Bond Performance Bank Guarantee d. In case AIR is an Indian company, have copies of registration certificate and/or Memorandum of Articles along with authorization letter from top management of the Indian company in the name of a person acting as the AIR also been submitted with the application? e. Has copy of Agreement between applicant and the Indian company / individual, nominated as the AIR, also been submitted? f. Are copies of valid RBI clearance certificate for Indian Office / Branch of the applicant or any other relevant document for establishment of its Office / Branch in India provided? Are English translations of all the documents, which are in languages other than English, also available? Does the applicant undertake to bear inspection charges for all the inspections to be carried out by BIS at its premises before the grant of licence, including the arrangements and costs incidental thereto for travel and stay, visa, insurance, etc.? Does the applicant undertake to arrange, if required, services of translator (for translation in English) during the visits of BIS officers to its factory? Does the applicant agree to sign a legally binding agreement with BIS in the prescribed format? Does the applicant agree to submit an Indemnity Bond to BIS in the prescribed format? Does the applicant agree to furnish a Performance Bank Guarantee to BIS of US $ 10000/- (from a bank having its branch in India) in the prescribed format on the letter-head of the bank? Page 20

21 APPENDIX-B Page 21

22 APPENDIX-C S Name of Machine/Qty. Capacity Make Date of No purchase 1 Wire Drawing Machine 2 Dry Mixer 3 Wet Mixer 4 Cutting and Straightening Machines 5 Extrusion Press (Wire feeder, Extruder & Conveyor) 6 Electrode Name Printing Unit 7 Flux Stripping Machine 8 Hot Air ovens for Baking Quantity Page 22

23 APPENDIX-D Doc: STI/814/7 December 2004 SCHEME OF TESTING AND INSPECTION FOR CERTIFIACTION OF COVERED ELECTRODES FOR MANUAL METAL ARC WELDING OF CARBON AND CARBON MANGANESE STEEL ACCORDING TO IS 814:2004 (SIXTH REVISION) 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) 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 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 license shall be printed on the body of the container and on any other packaging unit. Where paper packing cases or wrappers are used the Standard Mark shall be applied in such a manner that it cannot be misused. Page 23

24 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 viii) Date of manufacture; ix) A cautionary note on safety during welding; x) Made in India, if required; and xi) License 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 mentioned any other information which is not related to IS specification, should preferably use separate label or demarcation for the same. 5. 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 license 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 of controlled chemical composition (Refer Cl. 8.2 of IS 814:2004). 5.2 TEST PAD: Weld pad for checking electrode properties shall prepared as recommended in Annex-F, G & H of IS 814: INITIAL TESTS: The initial tests shall be carried out once in a year Page 24

25 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. 6.1 QUALITY CONTROL TESTS: Weld deposit from each batch of electrodes shall be analysed for chemical composition and the results obtained shall be within the manufacturers acceptance limit. 6.2 The manufacturer shall declare the range of chemical composition of weld metal for each classification and brand of electrodes. 7.1 RAW MATERIAL TESTS: Routine analysis of each consignment of raw materials received in the factory shall be carried out and appropriate records maintained. 7.2 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. 8.0 PACKING AND STORAGE: Electrodes shall be packed and stored as per clause 11 of IS 814: 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. Page 25

26 Such material shall in no circumstances be stored together with that conforming to the specification 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 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 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 license. Page 26

27 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 Clause Requirements Test Method Clause Reference No. of Samples LEVELS OF CONTROL Lot Size Remarks 6. Core Wire for electrodes. 6 IS 814 One One sample from each cast or every 20 coils whichever is Parent metal for test pieces. less IS 814 One Each consignment If the material covered under BIS Certification Scheme, no further testing is required. -do- 3. Coating ingredients As per company standard 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 b) Length 7.1 -do- One Every half an hour. Maximum, minimum diameter of each coil of the wire should be recorded. c) Bare length of electrodes d) Concentricity of flux covering with core wire & do- One sample of each type & size Every hour 7.3 -do- -do- Every half an hour Sample tests to determine robustness, resistance to withstand normal conditions of handling and use and ability to burn or fire evenly should be carried out by the Inspecting officer during his visit. Page 27

28 5.2 Coating ratio 5.2 Annex B -do- -do- -do- 8.3 Initial Tests 8.3 IS 814 a) All weld metal mechanical tests for tensile and Impact 9.1 -do- One sample from b) Butt weld bend tests do- Once in a year. (Please refer el. 5.3 of the Scheme) c) Running performance test 9.3 -do- d) Increased metal 9.4 -dorecovery tests (for electrodes claiming e) Diffusible hydrogen 9.5 -doestimation test (for hydrogen controlled f) Radiographic quality 9.6 -dotest (for radiographic quality electrodes) 7. Periodic check test 8.4 -do- a) All weld metal mechanical tests for tensile and impact b) Running Performance test 9.1 -do- One sample from Once in a month 9.3 -do- -do- -do- (Please refer cl. 5.4 of the Scheme) 8.5 Quality control test 8.5 -do- One batch of electrodes Each batch (Please refer cl.6 of the Scheme) 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 Once in a shift carton of each size 13. Marking 13 -do- -do- Each Carton (Please refer cl.4 of the Scheme) Page 28

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