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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)

BIS logo BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION SCHEME

PRODUCT CERTIFICATION MANUAL

Diesel Engines

Doc No: Issue No: Date: Nov 2013 Page No. Prepared by: Head (RBO) Approved by:

Amendment Sheet



Diesel Engines


FORWORD This manual elaborates principle manufacturing processes, infrastructure and quality controls, Scheme of Testing and inspection ,Marking fee rates, guidelines for writing scope of licence and inclusion of new types, Size of sample to be drawn for testing and manner of sealing it, list of test equipments/facilities, testing charges, testing time and Test facilities at BIS labs/OSLs etc. This also outlines raw materials involved in manufacturing of the product. This manual aims in providing basic inputs and all essential aspects with the expectation of bringing uniformity in BIS certification activity of the product. This document is intended for internal use by BIS inspecting officers who should however do not treat such document as replacement for referred Standards or that of relevant Scheme for Testing and Inspection (STI).



Diesel Engines


Table of Contents

SECTION I PRODUCT Description of Product(s) Latest Indian Standard List of Referred Indian Standards Checklist for Submission of an application for GOL SECTION II RAW MATERIALS List of Important Raw Materials SECTION III MANUFACTURING PROCESS & IN-PROCESS QUALITY CONTROLS Manufacturing Process & Control Section Infrastructure for production SECTION IV CERTIFICATION CRITERIA Identification of critical requirements of IS 11170:1985 Scheme of testing and inspection Marking fees Guidelines for writing scope of licence Guidelines for inclusion of new varieties Sample Size Manner of sealing sample Handling of Remnants SECTION IV INSPECTION AND TESTING Packing material requirement for samples List of required Test Equipment/facilities and frequency of calibration Status of Test Facilities in BIS Labs and OSLs with Testing Charges, and approximate time required for testing by BIS Labs/OSLs Basis for Grant of Licence Details of Tests to be carried out in factory SECTION V OTHER IMPORTANT ASPECTS



Diesel Engines


SECTION I

PRODUCT DESCRIPTION



Diesel Engines


SECTION I PRODUCT DESCRIPTION

a) Product Description:

Diesel Engines Diesel Engines set is commanally used for drawing water from the waterbed for domestic and industrial and agricultural purposes for driving and running the machines also. The standard IS 11170:1985 for Diesel engines sets (constant speed compression ignition (Diesel) Engine (up to 20 kW) which was first published in 1985. The constant speed compression ignition (Diesel) Engine set are of two categories

1. Constant speed Diesel Engines sets for general purpose Constant speed Diesel Engines sets for agriculture purpose

The constructs part of the Constant speed Diesel Engines sets essentially consists of the following:

a) Crank case b) Cam shaft bush c) Tapper roller bearing d) Drain pipe. e) Studs f) Rocker adjustment g) Fulcrum pine h) Gear cover plate i) Nuts and buts of different sizes j) Plane washer k) Main bearing housing l) Gasket and seals m) Joint for cover plate n) Oil deflector o) Oil seal p) Fuel pump bracket q) Fuel pump tapped r) Spring washer s) Fuel pump rocker lever t) Joint Flc u) Fuel pump rocker lever spindal v) Deep stick w) Cylinder block x) Cylinder liner y) Liner joint ring z) Sheems aa) Water flange(in case of water cooled diesel engine) bb) Push road cover cc) Cylinder head



Diesel Engines


dd) Valve rocker assembly ee) Rocker shaft ff) Spring for rocker arm gg) Decompration shaft hh) Decompression lever ii) Knob for decompression shaft jj) Knob for rocker box kk) Core plug for rocker box ll) Crank shaft

mm) Flywheel nn) Flywheel key oo) Tapper roller bearing pp) Lubricating oil pump qq) Lubricating oil strainer rr) Crank shaft gear wheel ss) Retaining cup tt) Bearing plate uu) Balancing weight vv) Connecting rod ww) Piston ring xx) Piston yy) Small and bush zz) Gudgeon pin aaa) Circlip bbb) Connecting rod bolt ccc) Cam shaft ddd) Cam shaft gear eee) Gov. push rod fff) Wall tapped ggg) Extension shaft hhh) Gov. Weight iii) Gov. Spring jjj) Cam shaft bush kkk) Oil seal lll) Fuel pump

mmm) injector nozal nnn) Fuel pump ooo) Speeder spring ppp) Air cleaner qqq) Manifolds etc......

Are the essential parts of any Diesel Engine



Diesel Engines


b) LATEST INDIAN STANDARD:

a. IS 11170:1985 Specification for performance requirements for constant speed compression ignition (Diesel) Engines for agriculture purposes up to (20 kW)

Amendments 1 to 5

c) List of referred standard

i) IS : 10000 (Part I) Glossary of terms relating to test methods. ii) IS : 10000 (Part II) Standard reference conditions. iii) IS : 10000 (Part III) Measurements for testing, units and limits of accuracy. iv) IS : 10000 (Part IV) Declarations of power, efficiency, fuel consumption and

lubricating oil consumption. v) IS : 10000 (Part V) Preparation for tests and measurements for wear. vi) IS : 10000 (Part VI) Recording of test results vii) IS : 10000 (Part VII) Governing tests for constant speed engines and selection of

engines for use with electrical generators. viii) IS : 10000 (Part VIII) Performance tests ix) IS : 10000 (Part IX) Endurance tests x) IS : 10000 (Part X) Tests for smoke levels, limits and corrections for smoke levels for

variable speed engines xi) IS : 10000 (Part XI) Information required with inquiry or order and information

supplied by the manufacture with the engine, and xii) IS : 10000 (Part XII) Test certificates

d) CHECK LIST FOR SUBMISSION OF AN APPLICATION FOR GOL

As per annexure A



Diesel Engines


Section II Raw Materials and components



Diesel Engines

Doc No: Issue No: Date: Nov 2013 Page No. Prepared by: Head (RBO) Approved by: The raw material various components are as given in the respective drawing along with the technical specification of raw material and refer standard. It varies with the manufacturer to manufacturer.



Diesel Engines


Section III

Manufacturing Process and In- Process Quality Control



Diesel Engines


Section III

a) Manufacturing process and in process quality control

Description of manufacturing process for Diesel engine 1) Castings/Machined components are procured from approved suppliers as per

drawings 2) After procurement of casting and components from the relevant parties, 100%

inspection of critical components carried out as per the required sizes. The castings are checked for soundness with the help of hydraulic pressure and only sound castings components are used for assembly.

3) It is to ensure that each component of diesel engine purchased bears a test certificate of the supplier. To ensure the conformity of the composition, the counter check of raw material is carried out in the outside lab and test certificates are ensured to be available for inspection.

4) After ensuring the dimensional check the confirming machine component are assembled and in process the various clearances required for smooth running are ensure by petrol inspection by way of in process quality control.

5) After assembly engines are tested as per the relevant part of IS 10000 for the related requirement as mentioned above in relevant standard.

b) In process quality control 1) Routine testing

Assembled engine are coupled through flexible coupling of the Dynamometer. The Engine is allowed to warm up in the coupled condition and run for 2 to 3 hours for warming up and stabilizing temperature. Once the temperature stabilized load is implied on the engine from the dynamometer in steps. And readings are taken as per the standard.

During the testing temperature of exhaust flue gases and initial gas

temperature is taken for the purpose of calculation. After that the governing test is carried out by running the engine at rated

speed, Rated output. Suddenly relieved load and check the momentary change percentage of speed and should be ensure that it is within the 15% and permanent change % of rated speed is within 8% of the specified rated speed for class B 1 governing.

2) All the engines which meets this specification requirements are sent for painting

and applying of rating plates and standard marks etc... before sending them to finish good store from where the engines are dispatched as per the orders.



Diesel Engines


Manufacturing flow chart for Diesel engine

Machined components purchased from vendors

Inspection of all components with requirements as declared in the drawings

Physical and chemical test of the critical components got done

Testing for routine test

Grinding and chipping of components wherever necessary

Sub- assembly & main assembly with intermediate checks

Painting

Packing

Dispatch



Diesel Engines


b) Infrastructure for production The following manufacturing facilities/ machinery are necessary for manufacturing of submersible pump The manufacturing facilities. No manufacturing machinery is required for manufacturing as all components are received in machined conditions as per drawings. Only assembly tables – tools likes spanner, mallet and torque wrench are required in assembly.

c) In process quality control 1. Cast iron components are checked towards casting defects 2. All machine components are verified as per the drawings and sizes 3. The free running of piston in cylinders checked and assembly checks are carried

out during manufacturing and assembly of Diesel engine sets. 4. Fly wheel balancing is done. 5. Hydraulic testing is carried out on components like cylinder head, cylinder liner

etc... before assembly.



Diesel Engines


SECTION IV Certification Criteria



Diesel Engines


SECTION IV Certification Criteria

a) Identification of critical requirements of the Indian standard

Note: To be provided by CMD

b) Scheme of Testing and Inspection Enclosed as annexure B

c) Marking fee rates Description Value

Unit 1 ENGINE L S Marking Fee 34000 S S Marking Fee 29000 Slab 1 Rate 17.3 Slab 1 Qty 1500 Slab 2 Rate 10.4 Slab 2 Qty Rest Slab 3 Rate 0 Enforcement Date 20120806 Remarks

d) Grouping guidelines

There is no grouping guidelines for Diesel engine as per IS 11170:1985.

e) Guidelines for scope of writing

While writing the scope of Diesel engine followings points are to be kept in consideration

1) Model No is mentioned 2) Diesel engine type horizontal or vertical – Type of cooling- water

cooled or air cooled, power rating - RPMs – SFC – IS rating – Governing class – lubricating oil consumption - lubricating oil specification – type of bearings – type of piston – balancing type – injection type i.e. direct or indirect – fuel type – fuel consumption are to be specified.

f) Guidelines for Inclusion of new variety There is no guidelines for Inclusion of new variety Diesel engine as per IS 11170:1985 in existing licence.



Diesel Engines


g) Sampling Plan

Sampling plan to be followed as as per the STI given by CMD

h) Manner of sealing of samples As per the prevailing practice at RBO, the samples are signed by IO, then they are sealed with sealing wax and brass seal/ lead seal The code number is written on the tag as well as on the Diesel Engine.

i) Remnants Since Diesel Engine is costly item remnants of the Diesel Engine after testing are returned to the licensee/applicant.

j) Procedure to be followed for destroying/ reshaping/ recycling the Non confirming products

In Diesel Engine, the Diesel Engine which do not meet the requirements are normally sold without BIS standard Marks or reassembled after changing the components found defective/ or effecting the efficiency of Diesel Engine i.e. piston assembly or cylinder head and piston gap etc.... depending on the situation



Diesel Engines


SECTION V INSPECTION AND TESTING



Diesel Engines


SECTION V INSPECTION AND TESTING

a) Packing material requirements (to be available in factory at all times) for

packing/ Dispatch of samples

No Packing material required for packing of Diesel Engine set sample. Since no packaging material is required for Diesel Engine, additional material to be available with the firm at the time of inspection or for sealing of sample following material is required.

1) Self adhesive stickers for making the tags to be a fixed on motor and submersible pump.

2) Brown labelling tags to be a fixed with the packaging material. 3) Sealing wax 4) Thread for tieing sealing wax and seal for dispatch of sample to independent lab.

b) List of test equipment facilities with requirements and frequency of

calibration

This detail is to be provided by CL.

c) Status of Test facilities in BIS lab/ OSL

List of BIS Laboratories

Lab Quantity Lab Type

Testing Facility Remarks

IS Number :- IS 11170 - 0 : 1985

PBOL 1no. Mech P Performance test only, Rating 5.9 kw,1500/1600 rpm

IS No. Testing Charges

Remarks

IS 11170 : 1985 Rs 24825/- 3.55 kW

Testing Facility:: C=Complete Test facility / P=Partial Test Facility/ N=No Test Facility



Diesel Engines


List of Outside Recognized Laboratories

IS Number :- IS 11170 - PERFORMANCE REQUIREMENTS FOR CONSTANT SPEED COMPRESSION IGNITION (DIESEL) ENGINES FOR AGRICULTURAL PURPOSES (UP TO 20

KW)

Sl No.

Name of the Recognized Laboratory Lab Code Testing Charges Remarks

1 NSIC Technical Services Centre 80 Ft. Road, Near Bhavnagar Road Crossing, Aji Industrial Area Rajkot-360003 Gujarat Contact : Shri N.K. Subramani, Deputy General Manager Tel : 0281-2387613,2387396 Fax : 0281-2387729

7104734 Single Cylinder Upto 8 KW for Type Test Rs.36000/- & Performance Rs.4680/-, Single Cylinder above 8 KW to 20 KW for Type Test Rs.36000/-& Performance Test Rs.6840/-; Double Cylinder Upto 8 KW for Type Test Rs.43200 & for Performance Test Rs. 6840/-, Double Cylinder 8 KW to 20 KW for Type Test Rs.43200/- & for Performance Test Rs.8640/-; Three Cylinder upto 20 KW for Type Test Rs.50400/- & for performance Test Rs.10440/-; Four Cylinder upto 20 KW for Type Test Rs.57600 & for Performance Test Rs.12600/-

2 Electrical Research & Development Association P.B. No. 760, ERDA Road, Makarpura Industrial Estate Vadodara-390010 Gujarat Contact : Dr. M.K. Shah, JD&Quality Manager -Mob:09978940911 Tel : 0265-2642942,964,377 Fax : 0265-2648382

7101125 Single cylinder- Rs.43170/-**, Double cylinder- Rs.50910/- ** [25% discount for BIS]

** Fuel charges and oil charges will be at actuals.



Diesel Engines


Basis of Grant of Licence The Grant of Licence in case of Diesel engine is granted based on the

independent test report only.

d) Details is tests to be carried out in the factory in case of: 1) Applicant/verification samples- Complete testing as per IS 11170:1985 for is

possible. 2) Surveillance/ Market samples- loop test as per IS 11170:1985 is possible. 3) Raw material samples to be got tested: form outside lab NABL approved lab and

verification of test certificates from manufacturer as well as cross conformity test got done by the firm.

4) Drawings to be checked for verification of components and to be supplied a copy of complete set to the lab for checking of wear and tear limits during the performance test.

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Download - BUREAU OF INDIAN STANDARDS (Western Region Office ...BIS logo BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION SCHEME PRODUCT CERTIFICATION MANUAL Diesel Engines Doc No: Issue No:

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