subject: implementation of is 9798:2013 low pressure ... · pdf filesubject: implementation of...

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CENTRAL MARKS DEPARTMENT-II (Legal)

Our Ref: CMD-II/16:9798 14 January 2015

Subject: Implementation of IS 9798:2013 Low Pressure Regulators for use with

Liquefied Petroleum Gas (LPG) – Specification (Second Revision).

The revision of IS 9798:1995 as IS 9798:2013 has been informed to all ROs/BOs vide our

note no. CMD-II/16:9798 dated 12 09 2014 (hosted on intranet on 15 09 2014) which

will come in force with effect from 31 01 2015.

FRBO was requested to prepare the STI and the guidelines as per revised IS 9798:2013

as desired by the CA. Thereafter all ROs/BOs were advised to make followup action and

send comments/difficulties if any if expressed by the licensees/applicants to FRBO for

finalization of revised STI and guidelines in implementation of revised standard vide our

note dated 29 10 2014.

The draft STI and related switchover guidelines for the existing licensees have been

circulated to all concerned by hosting on the intranet and website on 01 01 2015.

The new/revised STI Doc: STI/9798/6, January 2015 and the switchover guidelines are

enclosed for forwarding to all licensees and the applicants under their jurisdiction.

All ROs/BOs/SBOs are requested to initiate the action in implementation of revised IS

9798:2013 as per the enclosed guidelines on priority so that the same can be completed

by its specified time.

(Sunil Kumar)

Sc.F

Head CMD-II (Legal)

Circulated to all ROs/BOs/SBOs/BIS Labs.

Copy to: Head ITSD – With a request to host this circular on BIS intranet and website.

: Head (FRBO)

: Head (MED)

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Doc:STI/9798/6 January 2015

SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF

LOW PRESSURE REGULATORS FOR USE WITH

LIQUIFIED PETROLEUM GAS (LPG)

ACCORDING TO IS 9798:2013

1. LABORATORY: A laboratory shall be maintained which shall be

suitablyequipped 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

insuitable 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 Calibration of Testing instruments/equipments shall be carried out periodically

from NABL accredited calibration laboratories wherever they are available in the

same city. In case where such laboratories are not available, traceability to a

National Measurement System (NPL) to be ensured. All records of such

calibrations to be kept 2.3 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,

StatisticalQuality 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),

IS 397(Part 2) and IS 397 (Part 3)]. 3.1 In addition, effort should be made to gradually introduce a quality Management

system in accordance with IS/ISO 9001 series as appropriate to the activities of

the organization. 4. STANDARD MARK: The Standard Mark, as given in Column (1) of the

firstSchedule of the licence, shall be marked on each low pressure regulators for

use with LPG, provided always that the regulator to which this Mark is thus

applied conforms to every requirement of the specification. 4.1 MARKING: In addition each regulator shall be provided with the

followinginformation on the regulator:

a) The manufacturer’s name or trade mark; b) The month and year of manufacture;

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c) Rated capacity in m3/h of LPG.

d) Serial number of regulator, if required;

e) Number of this Standard .

f) Any other markings as agreed to between the purchaser and the

manufacturer; and

g) License Number (CM/L……….)

NOTE: The location and size of CM/L number to be marked on regulators is given in

Annex D. 5.0 CONTROL UNIT: A CU shall consist of a lot of bodies and cover of the same type

and size casted in a day from the material (body and cover can be cast on different days)

of the same consignment/supplier under similar process of production. 6.0 LEVELS OF CONTROL: The tests, as indicated in Table 1 attached and at

thelevels 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 Standards and covered by the licence shall be marked with

certification mark of the Bureau. 6.1 Each control unit of finished regulators shall be offered for inspection to BIS

before dispatch. The sampling and criteria of conformity for the lot inspection

given in Annex A of this scheme shall be followed; Regulators failing to meet the

requirements of the specification shall not be marked with the BIS Standard

Mark. 6.1.1 A certificate shall be issued by the Bureau in respect of regulators approved for

marking with BIS Standard Mark as per proforma given at Annex ‘B’. 6.2 The material shall conform to the requirements specified in Clause 4.1 and 4.2 of

IS 9798:2013. A test certificate shall be supplied by the supplier for each

consignment of material. However, cross check is to be carried out once in month

by testing samples at NABL approved laboratory. 6.2.1 Material of the diaphragm, valve pad &seals shall conform to the requirements as

specified in clause 4.3, 4.4 and 4.5 respectively of IS 9798:2013. A test certificate

shall be supplied by the supplier for each consignment of material. The frequency

of different tests shall be as indicated in Table 1.

6.2.2 The Bureau shall have the discretion of making an independent check test, if

necessary, Material of body, cover, diaphragm, valve pad and seals.

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6.3 At the time of approval of prototypes, the regulator shall be checked, for

conformity to all the requirements of IS 9798:2013. Whenever there is a change in

material or design of the regulator, it shall be retested and shall conform to all the

requirements of the specification. A drawing giving outline dimensions and

materials of construction shall be provided along with the prototypes.

7.0 In respect of all other clauses of the specification and at all stages of

manufacturer, the factory shall maintain appropriate control and checks to ensure

that their product conforms to the various requirements of the specification. 8.0 REJECTIONS: A separate record shall be maintained giving informationrelating

to the rejection of the production not conforming to the requirements of the

specification and the method of its disposal. Such material shall in no

circumstances be stored together with that conforming to the specification. 9.0 SAMPLES: The licence shall supply, free of charge, the samples required

inaccordance 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. 10.0 REPLACEMENT: Whenever a complaint is received soon after the goods

withStandard 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. 10.1 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. 11.0 STOP MARKING: The marking of the product shall be stopped underintimation

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 of Bureau.

11.1 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.

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12.0 PRODUCTION DATA: The licensee shall send to BIS production data duly

authenticated by a Chartered Accountant at the end of every operative period as

per item (b) of column 4 of the second schedule of the license, in the form

CM/PF/604.

Table 1……….

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ANNEX A (Cl. 6.1 of STI)

Subject: Sampling Plan for Lot Inspection for Certification of LPG regulators as per

IS 9798:2013. All the regulators of the same size manufactured from the same consignment of material

under similar conditions of production shall be grouped together to constitute a lot. The

lot may consist of one or more control units. Samples for lot inspection shall be selected

depending on the number of regulators in a lot as given below:

Lot Size Sample Size

Up to 500 20

501 1000 32

1001 3000 50

3001 10000 80

10001 25000 125 25001 & above 125 + (2nos per each

additional thousand or part there off) Note: When a lot consists of more than one control unit , the sample size shall be divided, as far as possible, equally between the control units Criteria for Acceptance of a lot –

(i) Each of the regulator selected in the sample shall be subjected to the following

tests:

a) Construction and workmanship including knob operation (clause 5.2).

b) Inter-changeability (Cl. 5.3).

c) Pneumatic test (Cl. 6.2, 6.4).

d) Performance test (Cl. 8.9.1).

e) Chatter (Cl. 8.9.2).

(ii) 2 regulators from the selected samples of each lot shall be tested for ;

a) Outlet connection: [2 for non-threaded (Cl. 5.6.1) & 10 % of sample size

for threaded (5.6.2).

b) Excess flow valve (5.9), if regulator is to be used with excess flow valve -

(one Regulator)

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c) Hydrostatic test (Cl. 6.3).

d) Mechanical Strength of Connection (8.11).

A regulator failing to meet any of the requirements of above tests shall be termed as

defective. The lot shall be accepted if no defective is found in the sample size, In case of

failure(s), the entire control unit(s) of the defective regulator(s) to be rechecked for the

failed parameter and reoffered for inspection, after taking corrective action, wherever

required.

If a control unit has been re-offered, then the same sampling criteria should be

applied as indicated above,but with double the sample size.

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ANNEX B (Cl. 6.1.1 of STI)

BUREAU OF INDIAN STANDARDS

(…………. REGIONAL OFFICE)

TEST CERTIFICATE FOR LPG PRESSURE REGULATORS

Certificate No. : Date:

Name and address of the manufacturer:

Batch No.(s) : Order No. & Date:

Purchaser :

Description: Low Pressure LPG regulator (Max. working Pressure 16.87 kgf/cm2) 500 l/h

outlet for 6.4/7mm Rubber Tubing to be used on SC valves with 22.0/25.6 mm outlet diameter. This is to certify that the following regulators are inspected and tested on ________ at

M/s _________ in accordance with Scheme Of Testing and Inspection attached with BIS

License No._________ meet the requirement of IS 9798:2013 & drawing

No.___________ approved by Chief Controller of Explosives vide letter No._________

dated _________. Raw Material Specification:

Supplier’s Name: Test Cert. No. & Date:

Chemical Composition (%)

------------------------------------------------------------------------------------------------------------ A1 Mg Cr Pb Fe Zn Impurities

------------------------------------------------------------------------------------------------------------

Specified

------------------------------------------------------------------------------------------------------------

As per T.C.

------------------------------------------------------------------------------------------------------------

Remarks

------------------------------------------------------------------------------------------------------------

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Doc:STI/9798/6

January 2015

Regulators bearing serial Nos from ………… to ………. covered by Lot no: ……

andControl Unitnos………. are checked/tested for thefollowing:

Sr

No

Parameter Clause

No

Specified

value/ or as

per clause

No of

pieces

inspected

Result

1 Construction & workmanship

(including knob operation)

5.2 5.2

2 Interchangeability 5.3 5.3

3 Leak-proof test for inlet

connection

5.5 5.5

4 Soundness test 6

4.a Pneumatic test (kg/cm2) 6.4 17

4.b Pneumatic test (gf/cm2) 6.2 150

4.c Hydrostatic test (kg/cm2) 6.3 25.4

5 Outlet Connection 5.6 5.6

6 Chatter 8.2, 8.9.2 8.2,8.9.2

7 Performance test 8.9.1 Delivery

Pr. (mm of

W.C)

7.a Inlet pr: 0.5 (kgf/cm2) and

100 % flow rate (500 l/h)

8.9.1 225min

7.b Inlet pr: 17 (kgf/cm2) and 10

% flow rate

8.9.1 400max

7.c Inlet pr: 17 (kgf/cm2) and

lock up

8.9.1 450max

8 Excess flow valve 5.9 5.9

9 Mechanical Strength of

Connection

8.11 8.11

QUANTITY OFFERED: QUANTITY PASSED:

SR. NO. OF REGULATORS REJECTED:

Method of disposal of rejected regulators: De-shaped/Dismantled:

Firm’s Q.C. In charge: BIS Inspecting Officer Name : Name : Designation: Designation:

Date: Date:

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ANNEX C (Table 1 of STI)

Interchangeability Procedure for Leak-proof test for inlet connection of LPG pressure

regulator as per clause 5.5 IS 9798 and Table 1 of this Scheme. The manufacturer shall provide to the inspector two self closing spring loaded LPG

valves manufactured as per customer’s requirements, one with all tolerances on the minimum side and another with all tolerances on the maximum side for this check For checking proper fitment and locking up with self closing spring loaded LPG valves, regulators to be coupled with the two pieces of valves provided as above and hydrostatic/pneumatic tests carried out with the valve in open position at the pressure of

25.4 kgf/cm2 /17.0 kgf/cm

2 to check that there is no leakage from the regulator inlet

portion as also from the valve outlet and the regulator inlet joint (the regulator orifice to be closed to lock up position by applying pneumatic pressure greater than 450 mm of water column through outlet of regulator).

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Doc: STI / 9798/6 January 2015

IS 9798: 2013

LOW PRESSURE REGULATORS FOR USE WITH

LIQUIFIED PETROLEUM GAS (LPG)

TABLE 1 LEVELS OF CONTROL

(Para 6.0 of the Scheme of Testing and Inspection)

TEST DETAILS LEVELS OF CONTROL Remarks Clause

no

Nature of test/ requirement Test

method/

clause no

Reference

IS

No of

samples

Lot Size Frequency

4 Material

4.1 &

4.2

Body & Cover Material 4.1 & 4.2 9798, 742 one Each

consignment

Each

consignment

See Note 1

4.1 Components material 4.1 9798 one do do do

4.1.1

Brass parts

4.1.1 9798,

2305

one do do do

5.2, 5.3 Construction 5.2, 5.3 9798 Each

regulator

9 Sealing 9 9798 Each

regulator

Type Tests

4.3 Diaphragm Material

4.3.1 Porosity and surface

smoothness

4.3.1 9798 0.25%

subject to

a

minimum

of 8

All the

Diaphragm of

the same

quality in a

consignment

Each lot

consignment

See note 2

4.3.2 Clamping test

Ageing/Hardness

4.3.2

3 or 4

9798

3400 (pt

4)

one do do Test to be

carried out on

representative

slab/ button.

See note 2

4.3.3 Clamping test 4.3.3 9798 one do do See note 2

4.3.4 Pull out and burst Annex C 9798 One

sample

Per 1000

Regulators

or Part

thereof.

All the

regulators

assembled

in one day

Daily See note 2

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TEST DETAILS LEVELS OF CONTROL Remarks Clause

no


method/

clause no

Reference No of

samples

Lot Size Frequency

4.3.5 Immersion test for

diaphragm

Annex D 9798 one 1000

diaphragm

Each lot

consignment

See note 2

4.3.6 Flexible test 4.3.6 9798 one 1000

diaphragm

Each lot

consignment

See note 2

4.3.7 Compression set test 4.3.7,

Annex E 9798 one Each lot

consignment

Each lot

consignment

Test to be carried

out on

representative

slab/ button.

4.4 Valve pad Material

4.4.1 Porosity, pits,Surface

smoothness , low cold

flow, creep

characteristic

4.4.1 9798 0.25%

subject to

a

minimum

of 8

All the

Diaphragm

of the same

quality in a

consignment

Each lot

consignment

See note 2

4.4.2 Immersion test for valve

pad

4.4.2 Annex D

9798 one 1000 valve

pad

Each lot

consignment

See note 2

4.4.4 Immersion test for valve

pad fitted in its housing

4.4.4 9798 one 1000 valve

pad fitted in

its housing

Each lot

consignment

See note 2

4.5 Seals 4.5 9798 0.25

percent

subject to

a

minimum

of 8

O rings &

rubber

components

other than

diaphragm

& valve pad

of the same

quality in

consignment

do See note 2

5.5.1 & 6.3

Hydrostatic Test 5.5.1 & 6.3

9798 3 Each control

unit

Each control

unit

Note 3

5.7 Body 5.7 9798 3 Each control

unit

Each control

unit

5.9, 8.10 Excess flow valve 5.9, 8.10,

Annex-

F(F3)

9798 one One control

unit

once a month

15

Clause

no


method/

clause no

Reference No of

samples

Lot Size Frequency

5.10 Valve pad fitting 5.10 9798 one Once in six

month

And at the time

of type approval

or whenever

there is change

in design.

5.11, 8.11 Strength of connection 5.11, 8.11 9798 one -- do -- -- do --

8.10.1 Cycle test 8.10.1 9798 2 Weeks

production

Each week. See note 4

8.10.2 Low temp test 8.10.2 9798 4 Weeks

production

Each week.

8.10.3 High temp test 8.10.3 9798 4 Weeks

production

Each week.

Routine tests

4.2.1 Finish

Corrosion resistance 4.2.1 9798 one one control

unit

Each week.

9844

6 6009

4.2.1 Finish (Adhesion test for

painted or powder coated

surface)

4.2.1,

Annexue B 9798 one one control

unit

one control unit

4.4.5 Compression set 4.4.5

Annex E 9798 one Each

consignment

4.4.3 Ageing test/ Hardness 3 or 4 3400 (Pt.4) one do Test to be

carried out on

representative

slab/button.

4.5 Porosity….Ageing/Hardness/Compression set

4.4.1,4.4.3,

4.4.5 9798 0.25

percent

subject to

a

minimum

of 8

do do

5.4, 5.5.3 Screwed Ends Annex E 9798 Each

regulator

16

Clause

no


method/

clause no

Reference No of

samples

Lot Size Frequency

5.5 Interchangeability/Leakproof

test for inlet connection

Annex- C of

STI 0.25

percent

subject to

a

minimum

of 8

All the

regulators

assembled

in a day

5.5.2,

6.2 &

6.4

Pneumatic test 5.5.2,

6.2 &

6.4

9798 Each

regulator

Note 5

5.6 Outlet connection (non

threaded) 5.6.1 9798 3 Each control

unit

Each control

unit

Suitable

gauges to be

arranged.

5.6 Outlet connection

(threaded)

5.6.2 9798 Each

regulator

...do…

5.9 Excess flow valve 5.9,

Annex-F

(F 2 & last

para)

9798 3 Each control

unit

Each control

unit

8.2, 8.9 Chatter & Performance 8.2, 8.9 9798 Each

regulator

Note 1: In case material is received with test certificate indicating conformity to chemical composition of relevant IS

no further testing is required. However, cross check is to be carried out once in month by testing samples at

NABL approved laboratory.

Note 2: If any of the sample fails, twice the number of samples shall be tested from the same consignment. In case of

further failures, the entire consignment (lot) shall be rejected.

Note 3: In case of any change in back pressure it shall be construed as leakage through the pad/body and treated as

failure of the regulator. In such case, thrice the number of fresh samples shall be tested from same lot. In case

of further failures, the entire consignment (lot) shall be rejected.

Note 4: In the event of non completion of the test at the time of inspection by BIS in a particular week, cycle tests

carried out during immediate previous week may be accepted. Test results of on going cycle tests to be shown

to BIS in succeeding visit.

Note 5: For clause 6.4, in case of any change in back pressure it shall be construed as leakage through the pad/body

and treated as failure of the regulator. In such case, further investigation to be carried out to asertain the reason

for failure and action to be taken accordingly, and quality check to be strengthened in the affected area .

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