DRAFT PRODUCT CERTIFICATION MANUAL FOR COMMENTS Our Ref.CRO 22 / FRBO 20 Jan 2014 Please find enclosed the following draft certification manual : PRODUCT MANUAL ON ROTATIONAL MOULDED POLYETHYLENE WATER STORAGE TANKS AS PER IS 12701:1996 Kindly examine the draft product certification manual and forward your comments on the draft manuals. Last date for comments: 5 Feb 2014. Comments, if any, may please be made in the format as given below and mailed to FRBO, Faridabad at the following email id: fdo.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 S. K. Khanna Deputy Director General Central Region Bureau of Indian Standards, 9, B S Z Marg, New Delhi- 110002
PRODUCT MANUAL 1. PRODUCT MANUAL ON ROTATIONAL MOULDED POLYETHYLENE WATER STORAGE TANKS AS PER IS 12701:1996 2. Amendment Sheet - Including Amendment No. 2, June 2004 3. Foreword The product certification scheme of the Bureau of Indian Standards, now under Bureau of Indian standards Act 1986, is in operation for more than four decades covering a wide variety of products. The wide experience in the area has brought a fair amount of rationalization in the certification process. This has resulted in the formulation of the Operation Manual for Product Certification (referred to as OMPC in this manual) prescribing rules and practices generally applicable to all products. Product related rules/guide lines are periodically issued to cover the specific requirements of different products. Still, in view of the wide spread of the certification operations, differences are found in the application of these guidelines in the BIS certification offices in different parts of the country. Therefore, it has been decided to bring out Sectoral manuals as guideline documents covering certification requirements of specific products/group of products. This Manual, one in the series, has been prepared to ensure uniformity in the certification practices in respect of s covered by IS 12701. This manual is strictly an internal document intended for use by the certification marks officers of BIS. 4. Table of Contents I: Product Description 5. Description of Products(s) - Rotational moulded polyethylene water storage tanks with nominal service temperature from +1 0 C to +50 0 C. These tanks are not meant for underground applications. The standard is applicable only to Water storage tanks subjected to the following two conditions: a) Own hydrostatic head of water b) with uniform flat base support 6. Rotational moulded polyethylene water storage tanks, IS 12701:1996, Number of Amendments - 02 7. List of referred Indian Standards for raw materials/components and test methods IS No. Title IS No. Title 554: 1985 Dimensions for pipe threads 9845:1986 Methods of analysis for the where pressure-tight joints are determination of specific and/ are required on threads (third or overall migration of constituents revision). of plastic materials and articles
1879:1987 Malleable cast iron pipe fittings (second revision) intended to come into contact with foodstuffs (first revision) 2530:1963 Methods of test for polyethylene 10141:1982 Positive list of constituents of moulding materials and polyethylene in contact with poly-ethylene compounds foodstuffs, pharmaceuticals and drinking water 4905:1968 Methods for random sampling 7328:1992 High density polyethylene 10146:982 Polyethylene for its safe use in Materials for moulding and contact with foodstuffs, pharmaextrusion ceuticals and drinking water 8543 Methods of testing plastics 13360 Plastics Methods of testing: (Part 4/Sec 1): Part 4 Short term mechanical (Part 5/Sec 7) Part 5 Mechanical properties, Properties, I 8. Check list for submission of an application for grant of licence - Pl. see check list on BIS Intranet for applicants) II: Raw Material / Components 9. List of important Raw Materials / components, including those which are required to conform to the relevant Indian Standards Sl.No. Raw Material/Components 1. Polyethylene Resin stabalised with antioxidants 2. Master batch 3. Man-hole lids Relevant Indian Standard IS 7328:1992 III: Manufacturing Process and in-process Quality Controls 10. Description of Manufacturing Process Rotational moulded grade of Polyethylene resin duly stabilized with anti-oxidants is the main raw material used for the manufacture of Rotational Moulded Polyethylene Water Storage s. Polyethylene resin is first mixed with master batch manually to impart colour to tank. The mix is heated and is then send to extruder for making granules. The granules are then pulverized to convert the mix into a powder form.
The pulverized material is then fed to the rotational moulding die of required size where the final product takes shape. After the process of rotation the mould is cooled and the tank gets released from the mould. The tank is then finished manually with the help of knives and files. Infrastructure for production A list of the manufacturing machinery is given in Annexure 1 - Pl. see the proforma on BIS intranet) IV: Certification Criteria 11. Identification of critical requirements of the Indian Standard ( To be provided by CMD ) In simple terms, a critical requirement can be defined as one that affects the health and safety of the user and the performance of the product during the course of its use. Thus keeping in view the process of manufacture and application of the product the following requirements can be termed as critical:- a) Minimum wall and bottom thickness b) Resistance to impact c) Top Load resistance d) Tensile Strength 12. Scheme of Testing and Inspection (Please See the STI on BIS Intranet vide ref. STI/12701/3 dated 30-07-2004) 13. Marking Fee Rates : Minimum marking fee Rs. 51200/- 14. Grouping Guidelines Grouping guidelines (Pl. refer CMD circular No. CMD-III/16:12701 dated 08-01-2002). 15. Guidelines for writing Scope of Licence Following shall be mentioned while writing the scope of licence: a) Net capacity b) Type of - whether rectangular loft or cylindrical vertical tank c) Layer d) Whether tank is with lid or without lid
16. Guidelines for Inclusion of new Varieties For the purpose of inclusion of additional varieties in the existing licence, one sample from each group and type as given in grouping guidelines shall be tested for all the requirements of the specification. As far as possible, sample of higher capacity shall be drawn for testing. 17. Sample size, including guidelines for drawal of separate samples are required to be sent to different labs for testing. One sample from each group and type as given in grouping guidelines shall be tested for all the requirements of the specification. 18. Manner of Sealing of Sample (s) The sample drawn shall be labeled and wax sealed. 19. Whether remnants of sample(s) 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 The remnants of the samples tested shall be scrapped after the testing. 20. Procedure to be followed for destroying / deshaping / recycling the product that does not meet the quality parameters during regular production. The product that does not meet the quality parameters during regular production may be recycled/reworked. The addition of not more than 10% of the manufacturers own reworked material resulting from the manufacture of tanks only according to IS 12701 is permissible. V : Inspection and Testing 21. Packing Material requirement (to be available in factory at all times) for Packing / Dispatch of Samples. There is no requirement of packing material for this product. 22. List of required Test Equipment / Facilities with requirement and frequency of Calibration Enclosed in Annexure 2. 23. Status of Test Facilities in BIS Labs and OSLs with Testing Charges, and approximate time required for testing by BIS labs / OSLs. 24. Whether Grant of Licence will be based on:
Both factory testing and independent testing shall be covered for this product. 25. Details of Tests to be carried out in the Factory in case of GOL and Surveillance Visit a) Net Capacity b) Gross Capacity c) Overall Height d) Effective Height e) Overall Diameter f) Internal Diameter of Manhole g) Density (At 23c Without Carbon) h) Carbon black content i) Carbon black dispersion j) Weight of (without Lid) k) Visual Appearance for Flat Area WALL THICKNESS a) Resistance to deformation b) Resistance to Impact c) Tensile Strength at Yield d) Flexural Modulus LID TEST a) Wall thickness b) Carbon black content c) Carbon black dispersion d) Material of lid e) Visual Appearance
Annexure 1 LIST OF MACHINERY Sl.No. Machinery 1. Bi-axial M/c(Straight Arm with Turret & its accessories) 2. Rock N Roll M/c 3. Extruder with cooling tower 4. Pulveriser M/c 5. Scrap Cutter with Motor 6. Scrap grinder with Motor 7. Genset 8. Moulds (as per required sizes)
Process flow chart Raw Material LLDPE Granules Master Batch To make Coloured granules on EXTRUDER M/c. ToMake Coloured Powder on PULVERISER M/c. Roto Moulding Machine for making s Than goes Fitting for lid Visual Examination & Control Checks Through,Tape,scale vernier,micrometer Etc. Testing Marking Stock Despatch