bureau of indian standards (western region …bis.org.in/qazwsx/oth/4984.pdf · draft product...

BUREAU OF INDIAN STANDARDS (Western Region Office, Mumbai)

DRAFT PRODUCT CERTIFICATION MANUAL 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 [email protected]

Last date for comments: 3 Feb 2014.

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)

PRODUCT MANUAL ON CERTIFICATION OF HIGH DENSITY POL YTHYLENE PIPES FOR WATER SUPPLY

Prepared by Approved by

PRODUCT MANUAL ON CERTIFICATION OF HIGH DENSITY POLYTHYLENE PIPES

FOR WATER SUPPLY



Amendment Sheet



TABLE OF CONTENTS

Section 1: Product Description Description of Product Latest Indian standard no with product title and no. of amendments List of referred standards for raw materials / components and test methods Check - list for submission of an application for grant of licence Section 2: Raw Materials / Components Section 3: Manufacturing Process & In Process Quality Controls Description of Manufacturing Process Intermediate Point of Control Infrastructure for Production (Manufacturing Machinery) Section 4: Certification Criteria Identification of critical requirements of IS 4984 Scheme of Testing and Inspection Marking Fee rates Grouping Guidelines Guidelines for writing scope of licence Guidelines for Inclusion of new varieties Guidelines for drawl of samples for independent testing Manner of sealing of samples Remnants of samples

Section 5: Inspection and Testing

Packing material requirement (to be available in factory at all times) for packing / dispatch of samples List of test equipments / facilities Status of Test Facilities in BIS Labs and OSLs with testing charges Grant of Licence will be based on Details of test to be carried out in the factory




Forward : The Product Certification Scheme of Bureau of Indian standards, now under Bureau of Indian standards Act 1986 is an operation for more than 4 decades covering a wide variety of products. The wide experience in the area has brought a fair amount of rationalization in Certification process. This has resulted in the formulation of OMPC prescribing rules and practices applicable to all products. Product related rules/guidelines are periodically issued to cover specific requirements of different products. Still, in view of wide spread of certification operations, differences are found in application of these guidelines in BIS Certification Offices in different parts of the country. Therefore it has been decided to bring out sector 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 HDPE pipes covered by IS 4984. This manual is strictly an internal document indented use by the Certification Marks Officers of BIS. Scope: This manual covers requirements for HDPE pipes from 16 to 1000 mm nominal diameter of pressure rating from 0.25 Mpa to 1.6 Mpa in material grades PE 63, PE 80 & PE 100 for use for buried water mains and services and for water supply above ground, both inside & outside buildings, vis-a-vis IS 4984: 1995. At the time of writing this manual, IS 4984: 1995 was in force however standard is referred to as IS 4984 so that any revision to the standard does not influence the manual.



Section 1: Product Description

5. Description of Product: HDPE is known for its large strength to density ratio. The mass density of HDPE can range from 0.93 to 0.97 g/cm3. Although the density of HDPE is only marginally higher than that of LDPE, HDPE has little branching, giving it stronger intermolecular forces and tensile strength than LDPE. The difference in strength exceeds the difference in density giving HDPE a higher specific strength. HDPE is resistance to many different solvents and has a wide variety of applications. Pipes shall be classified by pressure rating corresponding to maximum permissible working pressure at 30o C. Minimum required strength of material in Mpa at 20o C for 50 years for different material grades as indicated at table 1of IS 4984 and maximum allowable hydrostatic design stress are also important parameters in design of the pipes. 6. Latest Indian standard no with product title and no. of amendments: IS 4984: 1995, High Density Polyethylene Pipes for Water Supply – Specification, no of amendments – 6 7. List of referred standards for raw materials / components and test methods; IS No. Title 2530: 1963 Methods of rest for polyethylene moulding materials and polyethylene Compounds

4905: 1968 Methods for random sampling 7328: 1992 High density polyethylene materials for moulding and ex-trusion (first revision)

9845: 1985 Determination of overall migration of constituents of plastics materials and articles intended to come into contact with foodstuffs - method of analysis

10141: 1982 Positive list of constituents of polyethylene in contact with foodstuffs, pharmaceuticals and drinking water

10146: 1982 Polyethylene for its safe use in contact with foodstuffs, pharmaceuticals and drinking water



8. Check - list for submission of an application for grant of licence

1. APPLICATIOPN FORM 2. CERTIFICATE AUTHENTICATING MFG. PREMISES LIKE SSI CERTIFICATE 3. ACKNOWLEDGEMENT FROM MINISTRY OF INDUSTRIES (FOR LARGE SCALE

UNITS) 4. REGISTRATION CERTIFICATE-G.S.T. 5. REGISTRATION CERTIFICATE-C.S.T. 6. REGISTRATION CERTIFICATE-CENTRAL EXCISE 7. PARTNERSHIP DEED

OR 8. MEMORANDUM AND ARTICLES OF ASSOCIATION 9. AUTHORITY LETTER/ POWER OF ATTORNEY 10. SALE DEED/ LEASE DEED 11. ACCEPTANCE OF SCHEME OF TESTING & INSPECTION (STI) 12. ACCEPTANCE OF MARKING FEES 13. BRAND NAME DECLARATION PROFORMA (WITH REGISTRATION

DOCUMENTS (IF REGISTERED) 14. DECLARATION REGARDING MANUFACTURING MACHINERY IN CM/PF-305 15. DECLARATION REGARDING TEST EQUIPMENTS IN CM/PF-306 16. CALIBRATION CERTIFICATES 17. DECLARATION REGARDING SAMPLES TO BE OFFERED DURING

PRILIMINARY INSPECTION 18. CONSENT LETTER FROM BIS APPROVED LAB. (APPLICABLE WHERE SOME

TEST/S ARE CARRIED OUT FROM OUTSIDE LAB.) 19. RAW MATERIAL DETAILS 20. MFG. PROCESS 21. PROCESS FLOW DIAGRAM 22. LAYOUT PLAN OF FACTORY 23. TEST RESULTS OF SAMPLES TESTED DURING PRILIMIINARY INSPECTION 24. ROUTE MAP 25. RAW MATERIAL TEST CERTIFICATES 26. LAB RECORDS FOR ROUTINE TESTS 27. INTERMEDIATE POINTS OF CONTROL 28. APPOINTMENT LETTER, PHOTOGRAPH AND QUALIFICATION CERT. OF Q.C.I. 29. DECLARATION REGARDING WATER AND POWER SUPPLY 30. LIST OF DEALERS 31. SELLING PRICE DECLARATION 32. UNDERTAKING REGARDING SHIFTING AND OF MANUFACTURING

MACHINERIES AND TEST EQUIPMENTS 33. PRODUCT SPECIFIC DECLARATIONS ( WHERE APPLICABLE)



Section 2: Raw Materials / Components

HDPE granules Master Batch

Section 3: Manufacturing Process & In Process Quality Controls

10 . Description of Manufacturing Process

Loading and drying process is done by mixture machine. HDPE granules and master batch are mixed in mixture as per requirements, the required temperature can be set through panel and time period can be controlled manually. Extrusion process is carried out in the main plant which consists of die, sizer and pin. The material from mixture is fed to the extruder machine which is set with recommended temperature through panel and hence melting of raw materials is done which passes through die, sizer and pin is formed into pipe of desired diameter and thickness. The hot pipe than passes trough cold water in water cum vacuum tank, water is kept cool by cooling tower. Subsequently marking is done by marking machine. The pipe is then pulled out by traction unit as per the requirements and then coiled which can be cut by cutter as per required length. Intermediate Point of Control: --- Traction and take up speed, ---Vacuum pressure, ---Temperature of barrel and die zone, ---O.D. and thickness of pipe 11. Infrastructure for Production (Manufacturing Ma chinery)

1. Mixture 2. HDPE Pipe plant consisting of extruder die head with die, sizer & pin of required sizes

(a list of die, sizer, pin & bush shall be prepared and verified, an illustrative list for the range 32 to 110 mm is enclosed)

3. Vacuum tank 4. Cooling tower 5. Water circulating pump 6. Air compressor 7. Automatic three liner machine (extruder) 8. Traction unit 9. Pipe winder (coiler) 10. Platform weighing balance



Section 4: Certification Criteria

12. Identification of critical requirements of IS 4984: Width and depth of three equidistant stripes of blue colour as at clause 4.2 is treated as non-critical requirement, all remaining requirements of IS 4984 are treated as critical. 13. Scheme of Testing and Inspection: Doc: STI/4984/6, April 2004(copy enclosed)



14. Marking Fee rates: Rs. 86.40 per unit (Unit = 1 Tonne) with minimum marking fee of Rs. 29200/- for Small scale & Rs 36200/- for Large scale during an operative period of one year. 15. Grouping Guidelines – enclosed



16. Guidelines for writing scope of licence: High Density Polyethylene Pipes for Water Supply An illustration for sizes 32 to 110 mm for different material grades, pressure ratings and sizes according to availability of die, sizer, pin & bush, samples offered as per grouping guidelines is given below: HDPE Pipes for following grades/sizes/pressure rating PE 63 PN 2.5 DN 63 to 110 PE 63 PN 4 DN 40 to 110 PE 63 PN 6 DN 32 to 110 PE 63 PN 8 DN 32 to 110 PE 63 PN 10 DN 32 to 110 PE 63 PN 12.5 DN 32 to 110 PE 63 PN 16 DN 32 to 110

PE 80 PN 2.5 DN 90 to 110 PE 80 PN 4 DN 50 to 110 PE 80 PN 6 DN 40 to 110 PE 80 PN 8 DN 32 to 110 PE 80 PN 10 DN 32 to 110 PE 80 PN 12.5 DN 32 to 110 PE 80 PN 16 DN 32 to 110

PE 100 PN 6 DN 50 to 110 PE 100 PN 8 DN 40 to 110 PE 100 PN 10 DN 32 to 110 PE 100 PN 12.5 DN 32 to 110 PE 100 PN 16 DN 32 to 110 17. Guidelines for Inclusion of new varieties: As per grouping guidelines, minimum of 20 to 25 nos for sizes up to 450mm and 10 to 5 nos for sizes 500 to 1000mm. List of die, sizer, pin & bush shall be prepared as illustrated earlier and verified in line with new varieties to be included. Samples shall be drawn for independent testing as per grouping guidelines. 18. Guidelines for drawl of samples for independent testing: Declaration of MFI & Density for all the three grades viz. PE 63, PE 80 & PE 100 shall be obtained from the applicant before drawl of samples. Copy of illustrative test request is enclosed.



Our Ref. : RBO / Marks To, Date: 201304 M/s

Subject : Testing of Samples Dear Sir(s), 1) We have pleasure in sending the sample(s) indicated below for testing by you. The test

may please be carried out in accordance with the Indian Standard(s) against the samples.

2) We are advising the party to deposit the sample(s) with you at an early date.

3) The testing charges will be borne by the applicant. We are advising the party to deposit the testing charges with you early to honour the bill submitted by you in due course. The test report(s), in triplicate, may please be sent to this office at an early date.

4) All Correspondence in this connection may please be treated as strictly confidential. Copy or copies of Test Report(s), either in full or in part, should not, in any case, be furnished to any person without our prior written consent.

5) The remnants of the sample(s), If any, may please be retained with you pending further instructions from us.

6) Kindly acknowledge receipt of this letter as well as the sample(s) and let us have your test report(s) at the earliest preferably....on..top..priority .

Thanking you, Yours Faithfully

ANNEXURE – 1 Code Description Number of Relevant Number(s) Test(s) Required Indian Standard(s)

Sample of 1 meter X 6 nos. each of HDPE pipes Rajkot/ABB/201304 / for water supply of following designations For all tests as per

AS/01to08 01-PE 63 PN 4 DN 40, IS 4984: 1995 02- PE 63 PN 4 DN 110, (6 Amendments) 03- PE 100 PN 10 DN 32, 04- PE 100 PN 10 DN 110,

05- PE 100 PN 16 DN 32, 06- PE 100 PN 16 DN 110,

07- Sample of HDPE granules, PE 63 08- Sample of HDPE granules, PE 100



19. Manner of sealing of samples: 500gms of HDPE granules of the grades for which samples are offered shall be packed in polyethylene bag, tied with thread and coded tag and wax sealed. 6 Samples of 1 mtr length shall be cut from the pipe, hole shall be drilled at one end of each piece, all the 6 pieces are stacked on each other, thread or wire to be passed through holes of each piece, both ends of thread or wire to be tied with each other and further with coded tag and sealed with wax or lead seal and BIS seal. 20. Remnants of samples are non returnable, to be cut and disposed off. 21. The product HDPE pipes for Water Supply is under voluntary certification scheme. Product that does not meet the quality parameters during regular production however generally meeting the market requirements can be sold as non ISI product after defacing the marking on pipes. In other cases the pipe to be converted into powder form and 10% of rework material can be mixed with fresh lot of manufacture. Rejected pipes of more than 10% to be cut and sold as scrap.



Section 5: Inspection and Testing

22. Packing material requirement (to be available in factory at all times) for packing / dispatch of samples:

1. Old HDPE/ jute bags 2. Thread / wire 3. Drill 4. Wax / lead seals 5. Tags with hole 6. Needle and thread for packing the sealed samples

23. List of test equipments / facilities: list is enclosed



24. Status of Test Facilities in BIS Labs and OSLs with testing charges: Available on BIS intranet www.bis.org.in / intranet Approximate time required for testing of samples: the maximum test duration is for 165 hours for type test and hence entire testing can be completed within 7 days from the date of receipt of samples by the lab depending on the capacity and availability of test facilities at the lab with respect to no of samples under test and no of pending samples. Approximate time observed for receipt of test report is generally 1 to 1.5 months. 25. Grant of Licence will be based on : Independent testing bases 26. Details of test to be carried out in the factory: Dimensional – O.D., wall thickness, length, ovality, MFR, Density, CBC, CBD, reversion test visual appearance

bureau of indian standards (western region …bis.org.in/qazwsx/oth/4984.pdf · draft product...

Documents