draft product certification manual for …mcm)is 5312.pdfnon slam and quick closing characteristics...
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DRAFT PRODUCT CERTIFICATION MANUAL FOR COMMENTS
Our Ref.: NRO/CHBO(MCM) 13 Jan 2014
Please find enclosed the following draft certification manual:
Swing Check Type Reflux (Non-Return) Valves For Water Works Purposes -
Specification Part 1 Single Door Pattern as per IS 5312 (Part-I) : 2004
Kindly examine the draft product certification manual and forward your comments on the draft
manuals.
Last date for comments: 28 Jan 2014.
Comments, if any, may please be made in the format as given below and mailed to CHBO(MCD) at
the following email id: [email protected].
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 in case comments are lengthy and cannot be incorporated in
the table.
BUREAU OF INDIAN STANDARDS
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
(Part-I):2004
PREPARED BY:MDCH-2 APPROVED BY
2
PRODUCT MANUAL
ON
SWING CHECK TYPE REFLUX (NON-RETURN)
VALVES FOR WATER WORKS PURPOSES —
SPECIFICATION PART 1 SINGLE DOOR PATTERN
AS PER
IS 5312 (Part-I):2004
BUREAU OF INDIAN STANDARDS
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
(Part-I):2004
PREPARED BY:MDCH-2 APPROVED BY
3
BUREAU OF INDIAN STANDARDS
MANAK BHAWAN,
9, B.S. ZAFAR MARG,
NEW DELHI-110 002
0.0-AMENDMENT SHEET
SR. NO. AMENDMENT NO. DATE PAGE NO CLAUSE NO
BUREAU OF INDIAN STANDARDS
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
(Part-I):2004
PREPARED BY:MDCH-2 APPROVED BY
4
0.1-FOREWORD
Swing Check Type Reflux (Non-Return)Valves for Water Works Purposesare very useful in
preventing back flow of water to the pump. These valves have minimum head loss and can be very
competitive in terms of long service life. These valves are very useful in waterworks pipelines to
reduce hammer effect. Non slam and quick closing characteristics have made this product a very
demandable one across markets.
In the formulation of 5312 (Part-I)due weight age has been given to international co-ordination
among the standards and practices prevailing in different countries in addition to relating it to the
practices in the field in this country
This product is manufactured all across the country; however maximum concentration of this Industry
is in the states of Punjab.
This Product Manual is intended to cover all elements needed for grant of a product certification
licence and its continued operation providing reference material that can be used in all Regional /
Branch Offices and by various applicants / licensees to ensure coherence of practice and
transparency.
BUREAU OF INDIAN STANDARDS
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
(Part-I):2004
PREPARED BY:MDCH-2 APPROVED BY
5
0.2 -TABLE OF CONTENTS
SECTION CONTENT DETAIL PAGE NO I PRODUCT DESCRIPTION 5 to 8
II RAW MATERIAL/COMPONENTS 9
III MANUFACTURING PROCESS & IN-PROCESS
QUALITY CONTROLS
10 to 12
IV CERTIFICATION CRITERIA 13 to 20
V INSPECTION AND TESTING 21 to 23
BUREAU OF INDIAN STANDARDS
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
(Part-I):2004
PREPARED BY:MDCH-2 APPROVED BY
6
PRODUCT DESCRIPTION
SECTION 1.1- DESCRIPTION OF PRODUCT
IS 5312: (Part 1) covers requirement forflanged reflux valves of single door, swing
check typeused for water works purposes of sizes 50 to 600 mm.Double disc check and
lift check valves are notcovered under the scope of this standard.
As per IS 5312 (Part 1) ,Reflux valves shall be designated by nominal pressure
(PN) defined as maximum permissible gauge working pressure (MPa). The nominal
pressure for the varioussizes shall be as follows:
Size of Valve Nominal Pressure
(mm ) M Pa
50 to 600 1.0 and 1.6
Reflux valves shall be of the following nominalsizes:
50, 65, 80,100,125,150, 200,250,300,350,400, 450,500 and 600 mm.
BUREAU OF INDIAN STANDARDS
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
(Part-I):2004
PREPARED BY:MDCH-2 APPROVED BY
7
The nominal size shall refer to the nominal bore of the water way. The actual bore at
any point shallnot be less than the nominal size given above.
SECTION 1.2-LATEST INDIAN STANDARDS WITH PRODUCT
TITLE AND NUMBER OF AMENDMENTS
IS 5312 (Part 1): 2004 SWING CHECK TYPE REFLUX (NON-RETURN)
VALVES FOR WATER WORKS PURPOSES —
SPECIFICATIONPART 1 SINGLE DOOR PATTERN
AMENDMENTS --02
SECTION 1.3- LIST OF REFERRED INDIAN STANDARDS FOR
RAW MATERIALS/COMPONENTS AND TEST METHODS
LIST OF REFERRED INDIAN STANDARDS
IS No.Title
210:1993 Grey iron castings — Specification (fourth revision)
318:1981 Specification for leaded tin bronze ingots and castings (second revision)
320:1980 Specification for high tensile brass rods and sections (other than forging stock) second revision)
341:1973 Black Japan types A, B and C (first revision)
638:1979 Specification for sheet rubber jointing and rubber insertion jointing (second revision)
778:1984 Specification for copper alloy gate globe and check valves for water works purposes ~fourth
revision)
1030:1998 Carbon steel castings for general engineering purposes (fifth revision)
1363 Hexagon head bolts, screws and nuts of product grade C
(Part 1): 2002 Hexagon .head bolts (size range M 5 to M 64) (fourth revision)
(Part 3): 1992 Hexagon nuts (size range M 5 to M 64) (third revision)
1538:1993 Cast iron pipe fittings for pressure pipes for water, gas and sewage (third revision)
1865:1991 Iron castings with spherical or nodular graphite (third revision)
2712:1998 Gaskets and pickings — Compressed asbestos fiber jointing (third revision)
2932:1993 Enamel, synthetic, exterior (a) undercoating (b) finishing —Specification (second revision)
3444:1999 Corrosion resistant alloy steel and nickel base castings for general applications— Specification (third
revision)
6603:2001 Stainless steel bars and flats — Specification (/first revision)
9862:1981 Ready mixed paint, brushing, bituminous, black lead free, acid alkali, water and chlorine resisting
14329:1995 Malleable iron castings
BUREAU OF INDIAN STANDARDS
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
(Part-I):2004
PREPARED BY:MDCH-2 APPROVED BY
8
SECTION 1.4 A-
CHECK LIST FOR SUBMISSION OF AN APPLICATION FOR GRANT OF
LICENCE: See Annex B below
BUREAU OF INDIAN STANDARDS
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
(Part-I):2004
PREPARED BY:MDCH-2 APPROVED BY
9
BUREAU OF INDIAN STANDARDS
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
(Part-I):2004
PREPARED BY:MDCH-2 APPROVED BY
10
SECTION 1.4 B-
BUREAU OF INDIAN STANDARDS
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
(Part-I):2004
PREPARED BY:MDCH-2 APPROVED BY
11
RAW MATERIALS/ COMPONENTS
The materials used for the manufacture of different component parts shall conform to the
requirementsgiven in Table 1 given below. Where alternative materials are specified in Table 1 these
maybe used subject to theirstipulation in the contract or order.
SECTION 2.1-
LIST OF IMPORTATNT RAW MATERIALS/COMPONENTS INCLUDING
THOSE WHICH ARE REQUIRED TO CONFORM TO RELEVANT INDIAN
STANDARDS
(See Table 1 below)
BUREAU OF INDIAN STANDARDS
PREPARED BY:MDCH-2
12
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
(Part-I):2004
APPROVED BY
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
BUREAU OF INDIAN STANDARDS
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
(Part-I):2004
PREPARED BY:MDCH-2 APPROVED BY
13
MANUFACTURING PROCESSES QUALITY CONTROLS
SECTION 3.1-DESCRIPTION OF MANUFACTURING PROCESSES (TYPICAL)
MANUFACTURING FLOW CHART (FOR C.I. & D.I.VALVES)
Pattern Shop
↓ Foundry ( Moulding/Core Shop/ Casting)
↓ Fetling Shop (Grinding & Cutting)
↓ Q/A Inspection
↓ Shot Blasting
↓ Machine Shop (Machining)
↓ Q/A Department (Inspection)
↓
Hydrostatic Test
↓
Finishing
↓ Coating
↓
Q/A Inspection
↓ Dispatch
BUREAU OF INDIAN STANDARDS
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
(Part-I):2004
PREPARED BY:MDCH-2 APPROVED BY
14
DESCRIPTION OF MANUFACTURING PROCESSES & QUALITY
CONTROL
In the Foundry sand moulds to be used in moulding boxes are prepared from the pattern by moulding
machine & hand molding and cores are made from the core boxes of the items which are to be cast. The
raw material metal is put into the crucible and melted using Cupola Furnace & Induction furnace. The
material is melted and cast in the mould. During melting various fluxes and de- oxidizing chemicals are
used.
The casting is fettled, inspected grinded and then shot blasted. The cleaned casting is put to machining for
different operations. After machining stage inspections are done. Hydro pressure test carried out followed
by bituminous coating. After final inspection of the finished product, it is ready for dispatch.
BUREAU OF INDIAN STANDARDS
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
(Part-I):2004
PREPARED BY:MDCH-2 APPROVED BY
15
SECTION 3.2 -INFRASTRUCTURES FOR PRODUCTION
Following infrastructure is generally required for production of Swing Check Type
Reflux (Non-Return) Valves For Water Works Purposes —Specification Part 1 Single
Door Pattern
Sl.No. Machinery Make Capacity Number Remarks
1
2
3
4
5
6
7
8
9
10
11
12
13
14.
Lathe Machine
(12’ Large)
Lathe Machine
(10’ Large)
Lathe Machine
(8’ Large)
Lathe Machine
(6’ Large)
Drill Machine
(1 +1/2 Cap)
Drill Machine
Hydraulic Testing
Machine With
mandals
Grinding Machine
Electric Grinder
Welding Machine
Cupola Furnace
Shot Blasting
Machine
Cutter Machine
Generator Set
80 to 600 mm
50 to 500 mm
50 to 500 mm
50 to 500 mm
50 to 600 mm
50 to 450 mm
50 to 600 mm
50 to 600 mm
50 to 600 mm
50 to 600 mm
8 to 10 Ton
Per Day
50 to 600 mm
2 Nos.
2 Nos.
3 Nos.
4 Nos.
2 Nos.
3 Nos.
2 Nos.
2 Nos.
3 Nos.
1 Nos.
1 Nos.
2 Nos.
1 No.
1 No.
For Turning, Facing,
Threading & Boring
For Turning, Facing,
Threading & Boring
For Turning, Facing,
Threading & Boring
For Turning, Facing,
Threading & Boring
For Drilling
For Drilling
For H.S.T. purpose
For Grinding Purpose
For Grinding Purpose
For Welding Purpose
For Melting Purpose
For Casting Finishing
Note: Adequate Electric Power and Water supply is required
BUREAU OF INDIAN STANDARDS
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
(Part-I):2004
PREPARED BY:MDCH-2 APPROVED BY
16
CERTIFICATION CRITERIA
SECTION 4.1 -CRITICAL REQUIREMENTS OF THE INDIAN STANDARD
(To be provided by CMD)
SECTION 4.2 -SCHEME OF TESTING AND INSPECTION
(See below)
BUREAU OF INDIAN STANDARDS
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
(Part-I):2004
PREPARED BY:MDCH-2 APPROVED BY
17
BUREAU OF INDIAN STANDARDS
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
(Part-I):2004
PREPARED BY:MDCH-2 APPROVED BY
18
BUREAU OF INDIAN STANDARDS
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
(Part-I):2004
PREPARED BY:MDCH-2 APPROVED BY
19
BUREAU OF INDIAN STANDARDS
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
(Part-I):2004
PREPARED BY:MDCH-2 APPROVED BY
20
BUREAU OF INDIAN STANDARDS
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
(Part-I):2004
PREPARED BY:MDCH-2 APPROVED BY
21
SECTION 4.3 -MARKING FEE RATES
Description Value
L S Marking Fee 34000
S S Marking Fee 29000
Unit 1 Valve
Rate of one unit Rs. 3.5
BUREAU OF INDIAN STANDARDS
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
(Part-I):2004
PREPARED BY:MDCH-2 APPROVED BY
22
SECTION 4.4 -GROUPING GUIDELINES:
BUREAU OF INDIAN STANDARDS
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
(Part-I):2004
PREPARED BY:MDCH-2 APPROVED BY
23
SECTION 4.5 -GUIDELINES FOR WRITING SCOPE OF LICENCE "SWING CHECK TYPE REFLUX (NON-RETURN)VALVES FOR WATER WORKS PURPOSES
—SINGLE DOOR - WITHOUT BYE PASS – WITH DOUBLE FLANGED ENDS
CONSTRUCTION OF BODY IN PRESSURE PN 1.0 & 1.6 IN SIZES FROM 50 MM UPTO AND
INCLUDING 125 MM;
150 MM UPTO AND INCLUDING 300 MM AND 350 MM UPTO AND INCLUDING 600 MM.”
SECTION 4.6 -GUIDELINES FOR INCLUSION OF NEW VARIETIES Same as Section 4.4
SECTION 4.7- SAMPLE SIZE
• Product-One sample comprising of one number of Swing Check Type Reflux (Non-Return)
Valve of any size (see clause 6 & 8 of IS 5312 (Part 1): 2004.
SECTION 4.8 -MANNER OF SEALING THE SAMPLE
Samples may be wrapped with suitable packing material, labeled and wax sealed or as an alternate
code no and signatures of IO may be marked with a permanent marker pen on the product.
SECTION 4.9 -REMNANTS ARE RETURNABLE/NON-RETURNABLE TO
BE SCRAPPED/USED OR TO BE DESHAPED DISPOSAL IN CASE
OFSAFETY ITEMS
Sample is normally consumed in testing and Remnants are not returnable and may be suitably
disposed off by the laboratory.
SECTION 4.10-
PROCEDURE TO BE FOLLOWED FOR DESTROYING/ DESHAPING/ RECYCLING THE
PRODUCT THAT DOES NOT MEET THE QUALITY PARAMETERS DURING REGULAR
PRODUCTION
BIS Standard Mark to be marked only after ascertaining the quality of the material after testing as per
Indian standard and STI.
BUREAU OF INDIAN STANDARDS
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
(Part-I):2004
PREPARED BY:MDCH-2 APPROVED BY
24
INSPECTION AND TESTING
SECTION 5.1-PACKING MATERIAL REQUIRED FOR PKG/DISPATCH
OF SAMPLE
Any suitable material may be used for wrapping the sample to avoid any damage during transit.
SECTION 5.2-LIST OF REQUIRED TEST EQUIPMENT/FACILITIES
WITH REQUIREMENT & FREQUENCY OF CALIBRATION
(To be provided by CL)
SECTION 5.3 -STATUS OF TEST FACILITIES IN BIS LAB AND OSL
WITH TESTING CHARGES AND APPROXIMATE TIME REQUIRED FOR
TESTING
For latest information, please check the BIS web site www.bis.org.in
or click the following link http://www.bis.org.in/lab/osl_query.asp?form_is=5312 Pt.(I)
&Submit=Run+Query
BUREAU OF INDIAN STANDARDS
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
(Part-I):2004
PREPARED BY:MDCH-2 APPROVED BY
25
List of BIS Laboratories
Lab Quantity Lab Type Testing Facility Remarks
IS Number :- IS 5312 - 1 : 2004
BNBOL 1No Mech P Ex material test
NROL 1 No Mech P except Hydrostatic above 300 mm & Chemical
IS Number :- IS 5312 - 2 : 1986
BNBOL 1No Mech P Ex material test
IS No. Testing Charges Remarks
IS 5312 - 1 : 1984 Rs 1200/- Excluding Material Material charges as per relevant ISS
Testing Facility:: C=Complete Test facility / P=Partial Test Facility/ N=No Test Facility
List of Outside Recognized Laboratories (As on 19 11 2013)
IS Number :- IS 5312 Part: 1 - SWING CHECK TYPE REFLUX (NON-RETURN) VALVE FOR WATER
WORK PURPOSES PT-1 SINGLE DOOR PATTERN
Sl
No. Name of the Recognized Laboratory Lab Code Testing Charges Remarks
1 MSME Testing Centre
M/o Micro,Small & Medium
Enterprises,Govt.of India
111&112 B.T. Road
Kolkata-700108
West Bengal
Contact : Sh. P. Ray, Director
Tel : 033-25770686/2482
Fax : 033-25771353
5108204 Rs.1875/-
2 M/s United Solutions Private Limited
C-245, Village: Allour, Bhadla
Road, Khanna
Distt.- Ludhiana
Ludhiana-141402
Contact : Shri Manoj Kumar,
Managing Director
Tel : 09417010448
Fax : 01628-238108
9126706 BIS Testing charges
BUREAU OF INDIAN STANDARDS
PRODUCT MANUAL ON SWING CHECK TYPE REFLUX (NON-
RETURN)VALVES FOR WATER WORKS PURPOSES as per IS 5312
(Part-I):2004
PREPARED BY:MDCH-2 APPROVED BY
26
SECTION 5.4 -WHETHER GRANT OF LICENCE WILL BE BASED ON
FACTORY TESTING BASIS---------------------------------------------No
INDEPENDENT TESTING BASIS--------------------------------------Yes
MIXED BASIS (FACTORY TESTING OF PRODUCTPLUS INDEPENDENT TESTING OF
SOME RAW MATERIALS)----------No
SECTION 5.5 -DETAILS OF TESTS TO BE CARRIED OUT IN FACTORY
IN CASE OF
APPLICANT/VERIFICATION SAMPLES
• Dimensions and tolerances as per clause 6.2 of IS 5312 ( Part-1)
• Hydrostatic Body Test as per clause 8.2&Hydrostatic Seat Testas per clause 8.3 of IS 5312 (
Part-1)
SURVEILLANCE SAMPLES
• Dimensions and tolerances as per clause 6.2 of IS 5312 ( Part-1)
• Hydrostatic Body Test as per clause 8.2 & Hydrostatic Seat Test as per clause 8.3 of IS 5312 (
Part-1)
• RAW MATERIAL SAMPLES TO BE GOT TESTED IF ANY -- As per clause 5 , table 1 of
IS 5312 ( Part-1)