DRAFT PRODUCT CERTIFICATION MANUAL FOR COMMENTS Our Ref.: NRO/PRBO 13 Jan 2014 Please find enclosed the following draft certification manual: Product manual on Rubber Hose for Liquefied Petroleum Gas as per IS 9573: 2012 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 PRBO 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. 1 FOR BIS USE ONLY Doc No.: PM/IS9573/01 PRODUCT MANUAL ON RUBBER HOSE FOR LIQUEFIED PETROLEUM GAS (LPG) Date of Issue: January 2014 2 BUREAU OF INDIAN STANDARDS PRODUCT MANUAL PRODUCT CERTIFICATION TITLE: GENERAL DOC: PC-9573 ISSUE: 01 DATE: NOV 2013 PREPARED BY: PAGE: 1 OF 4 APPROVED BY: AMENDMENT SHEET To ensure that each copy of the Manual contains a complete record of Amendments, this Amendment Sheet should be updated for each revised/new pages of the Manual. While issuing any amendment, an acknowledgment slip will be included for signatures and return by all Controlled Copy holders. DISCARD AMENDMENT No. Section Page Issue No. INSERT Date Section Page Issue No. SUMMARY OF CHANGE Date 3 BUREAU OF INDIAN STANDARDS PRODUCT MANUAL PRODUCT CERTIFICATION TITLE: GENERAL DOC: PC-9573 PREPARED BY: ISSUE: 01 DATE: NOV 2013 PAGE: 2 OF 4 APPROVED BY: FOREWARD: This Indian Standard (Second Revision) was adopted by the Bureau of Indian Standards, after the draft finalized by Rubber products Sectional Committee had been approved by the Petroleum, Coal and Related products Division Council. This standard was first published in 1980. In the first revision, requirements for flexibility and electrical continuity were included. In the swelling test, n-pentane was prescribed as test liquid in place of iso-octane and requirements for tensile strength and accelerated aging were also modified. In this second revision requirement for wire braided rubber hose for domestic/commercial installations have been included. Grip strength of hose, burning behavior and resistance to crushing requirements has been included. Swelling in test liquid requirements has been modified as resistance of liquid to n-pentane requirement. In addition to above, modifications have also been made in scope, proof pressure test and bursting pressure requirement. The hoses covered by this standard are suitable for use in LPG vapor phase and LPG/ air installations. This hose may also be put to ‘wet’ use that is, permanently filled with liquid and in the temperature range from 20 to +60°C. In the preparation of this standard assistance has been derived from ISO 2928: 1986. Rubber hose and hose assemblies for liquefied petroleum gases (LPG), and BS 3212-1991 ‘Specification for flexible rubber tubing, rubber hose and rubber hose assemblies for use in LPG vapor phase and LPG/ air installations’ and BS 4089-1989 ‘Hoses and hose assemblies for liquefied petroleum gases’. A separate standard IS 10908: 1991 has been prepared for flexible rubber tubing for liquefied petroleum gas. This standard contains Clauses 5.2.4, 5.3.3 and 6.1 which call for agreement between the purchaser and the supplier. Clauses 5.5.7 and 5.5.8 are for type 4 hose only and Clause 5.5.6 is for Type 1, Type 2 and Type 3 hoses only. 4 BUREAU OF INDIAN STANDARDS PRODUCT MANUAL PRODUCT CERTIFICATION TITLE: GENERAL DOC: PC-9573 PREPARED BY: ISSUE: 01 DATE: NOV 2013 PAGE: 3 OF 4 APPROVED BY: For the purpose of deciding whether the particular requirement of this standard is complied with, the final value, observed or calculated, expressing the results of a test or analysis, shall be rounded off in accordance with IS 2: 1960 ‘Rules for rounding off numerical values (Revised)’. The number of significant places retained in the rounded off value should be the same as that of the specified value in this standard. 5 BUREAU OF INDIAN STANDARDS PRODUCT MANUAL PRODUCT CERTIFICATION TITLE: GENERAL DOC: PC-9573 ISSUE: 01 DATE: NOV 2013 PREPARED BY: PAGE: 4 OF 4 APPROVED BY: TABLE OF CONTENTS Sections Title Page No. Section 1 Product Description 6-7 1.1 Description of product(s) 6 1.2 Latest Indian Standard Number with product title and number of amendments 6 1.3 List of referred standards 6-7 1.4 Checklist for submission of an application for grant of licence 7 Section 2 Raw materials/ Components 8 2.1 List of important raw materials/components 8 Section 3 Manufacturing process and In-process Quality controls 9-10 3.1 Description of manufacturing process(es) 9 3.2 Infrastructure for production 10 Section 4 Certification criteria 11-12 4.1 Identification of critical requirements 11 4.2 Scheme of testing and inspection 11 4.3 Marking fee rates 11 4.4 Grouping guidelines 11 4.5 Guidelines for scope of licence 11 4.6 Guidelines for inclusion of new varieties 11 4.7 Sample size and Guidelines for drawl of separate samples 12 4.8 Manner of sealing of sample(s) 12 4.9 Dealing with sample remnants 12 4.10 Procedure for destruction of non conforming product 12 Section 5 Inspection and testing 13-16 5.1 Packaging material requirement 13 5.2 List of test equipment/ facilities 13-15 5.3 Test facilities in BIS Labs/ OSLs with testing charges and approximate time 15 5.4 Basis of grant of licence 15 5.5 Details of tests to be carried out in the factory 16 Annex 1 Annexes Check-list for submission of an application for grant of licence 17 6 BUREAU OF INDIAN STANDARDS PRODUCT MANUAL PRODUCT CERTIFICATION TITLE: PRODUCT DESCRIPTION DOC: PC-9573 ISSUE: 01 PREPARED BY: DATE: NOV 2013 PAGE: 1 OF 2 APPROVED BY: SECTION 1: PRODUCT DESCRIPTION 1.1. Description of product: The product manual prescribes for rubber hose for liquefied petroleum gases (LPG) for a maximum working pressure of 2.5 MPa for Type 1, Type 2 and Type 3 hoses and 1.0 MPa for Type 4 hoses at a maximum temperature of 65° C. Type 1: Single or double braided or spirally lapped wire. Additional plies of either braided fabric or rubber may be applied immediately under or over the wire braids. Type 2: Textile plies in cord, woven or braided form, together with two or more electrical bonding wires of corrosion and fatigue material. Type 3: Textile plies in cord, woven or braided form, or metallic cord together with at least one helix of heavy steel wire embedded in the rubber. Type 4: Wire reinforced hose for domestic/commercial installations. 1.2. Latest Indian Standard Number with product title and number of amendments Indian Standard Number: IS 9573: 1998; Product title: Rubber hose for liquefied petroleum gas (LPG)- Specification (Second revision); No. of amendments: 3. 1.3. List of referred standards The following Indian Standards contain provisions which constitute the provisions of this standard: IS No. 443: 1975 3400 (Part 5): 1986 4576: 1978 7503 Title Methods of sampling and test for hoses (second revision) Methods for test of vulcanized rubber Part 5: Adhesion of rubbers to textile fabrics Liquefied petroleum gases (first revision) Glossary of terms used in rubber industry 7 BUREAU OF INDIAN STANDARDS PRODUCT MANUAL PRODUCT CERTIFICATION TITLE: PRODUCT DESCRIPTION DOC: PC-9573 PREPARED BY: ISSUE: 01 DATE: NOV 2013 PAGE: 1 OF 2 APPROVED BY: (Part 1): 1988 Definition of basic terms (first revision) (Part 2): 1988 Definition of additives (first revision) (Part 3): 1988 Definition relating to properties and testing (first revision) (Part 4): 1988 Definitions relating to processing (first revision) (Part 5): 1988 Definitions relating to product hoses (first revision) 1.4. Check-list for submission of an application for grant of licence: As per Annexure 1 8 BUREAU OF INDIAN STANDARDS PRODUCT MANUAL PRODUCT CERTIFICATION TITLE: RAW MATERIALS/ COMPONENTS DOC: PC-9573 ISSUE: 01 PREPARED BY: DATE: NOV 2013 PAGE: 1 OF 1 APPROVED BY: SECTION 2: RAW MATERIALS/ COMPONENTS 2.1. List of important raw materials/components Item Type Nitrile Rubber Nitrile-PVC Rubber Curatives Reterder Accelerator Zinc Oxide Acceleartor Acctivator Antidegradent Process Oil/ Plasticizer Process Aid Carbon Black White filler Colour Pigment Titanium Di-oxide Special Additives Few Example of Item Name Nitrile Rubber Nitrile-PVC Rubber Sulphur PVI CBS/ MBTS/ TMTD Zinc Oxide Stearic Acid SP-Oil TQ/ TDQ Pilflex-13/ 6PPD DOP/ DBP/DOA/DOS Fast Flow S/ WB-16/ Rubaid-16 Paraffine Wax/ MC Wax N660/ N762/ N550 Aluminium Silicate Calcium Carbonate/ China Clay Silica Orange colour/ Red Colour Titanium Di-oxide Antimony Tri-oxide/ Aluminium Tri-oxide 9 BUREAU OF INDIAN STANDARDS PRODUCT MANUAL PRODUCT CERTIFICATION TITLE: MANUFACTURING PROCESS DOC: PC-9573 ISSUE: 01 PREPARED BY: SECTION 3: CONTROLS DATE: NOV 2013 PAGE: 1 OF 2 APPROVED BY: MANUFACTURING PROCESS AND IN-PROCESS QUALITY 3.1. Description of manufacturing process A TYPICAL PROCESS FLOW CHART RAW MATERIAL RECIEVING ↓ COMPONENT MIXING AND ACCELERATION (OPEN MILL) ↓ LABORATORY TESTING ↓ INNER EXRTUSION ↓ BRAIDING ↓ OUTER EXTRUSION ↓ WRAPPING ↓ CURING ↓ UNWRAPPING ↓ MANDREL EXTRACTION ↓ TESTING ↓ PRINTING ↓ AIR IN WATER TEST ↓ HOSE CUTTING, CLEANING AND INSPECTION ↓ PACKING AND DESPATCH 10 BUREAU OF INDIAN STANDARDS PRODUCT MANUAL PRODUCT CERTIFICATION TITLE: MANUFACTURING PROCESS DOC: PC-9573 ISSUE: 01 PREPARED BY: DATE: NOV 2013 PAGE: 2 OF 2 APPROVED BY: 3.2. Infrastructure for production Following basic manufacturing facilities shall be available at applicant unit for the production of Rubber hose: i. ii. iii. iv. v. vi. vii. viii. ix. x. xi. xii. xiii. xiv. xv. Intermixing machine Dump mill Acceleration mill with Stock blender Cooling machine Mandrel Lubrication Unit Mandrel cleaning unit Cold feed Extruder Diameter Measuring & Control System Wire winding machine Braiding machine Wrap/unwrap machine Steam boiler Autoclave Mandrel extraction and hose testing machine Inkjet print machine The capacity and number of manufacturing machines or testing machines may vary as per production needs and applicability. In process quality controls shall be followed as per STI for the product. 11 BUREAU OF INDIAN STANDARDS PRODUCT MANUAL PRODUCT CERTIFICATION TITLE: CERTIFICATION CRITERIA DOC: PC-9573 ISSUE: 01 PREPARED BY: DATE: NOV 2013 PAGE: 1 OF 2 APPROVED BY: SECTION 4: CERTIFICATION CRITERIA 4.1. Identification of critical requirements All requirements documented in standard shall be considered critical unless mentioned otherwise. 4.2. Scheme of testing and inspection The STI for IS 9573 as in force shall be applicable i.e. STI/9573/2. The implementation of STI shall be verified during surveillance inspection. 4.3. Marking fee rates The details of rate of marking fee are available on BIS intranet/website. 4.4. Grouping guidelines No grouping guidelines are available for IS 9573: 1998. 4.5. Guidelines for scope of licence Licence shall be granted with scope specifying the type(s) of the product. Licence shall not be granted with “open scope”. The grant of licence letter and the Licence Document shall clearly indicate the following: a) Rubber hose for liquefied petroleum gas(LPG) with corresponding Indian Standard; b) Type of hose (Type 1, 2, 3, 4); and c) Maximum working pressure (1.0 MPa/ 2.5 MPa). 4.6. Guidelines for inclusion of new varieties For inclusion under the simplified procedure, in case the licensee submits the complete test report of containers from OSL along with modified process flow chart if any, additional infrastructure facilities if required, intermediate checks etc., inclusion as per the simplified procedure shall be permitted without any further testing. The variety so included may be drawn for independent testing during subsequent visits on rotational basis, so as to cover the entire range and the changes intimated shall be verified during the subsequent visit. 12 BUREAU OF INDIAN STANDARDS PRODUCT MANUAL PRODUCT CERTIFICATION TITLE: CERTIFICATION CRITERIA DOC: PC-9573 ISSUE: 01 PREPARED BY: DATE: NOV 2013 PAGE: 2 OF 2 APPROVED BY: The licensee shall submit an undertaking that in case of failure of sample in independent testing, he shall abide by the instructions of BIS for stop marking/withdrawal of permission to use the particular type of hose/cancellation of licence, as the case may be. Under normal procedure, the additional manufacturing and testing facilities shall be verified and sample be drawn for independent testing. Endorsement to the licence shall be issued for including the particular type/variety in the licence after sample of such variety is found conforming to the standard. 4.7. Sample size and Guidelines for drawl of separate samples Minimum 3 samples of 1.2/ 1.5m each shall be selected. 4.8. Manner of sealing of sample(s) Effort shall be made, as far as possible, to send samples without the manufacturer’s identification and/or markings. Any label and/or manufacturer's identification shall be removed or defaced. Test request shall clearly indicate the following: a) Date of manufacture; b) Quantity, c) Type/ grade of material 4.9. Dealing with sample remnants The remnants of samples may be disposed off after testing. 4.10. Procedure for destruction of non conforming product The non conforming hoses shall be scrapped off by cutting into pieces. 13 BUREAU OF INDIAN STANDARDS PRODUCT MANUAL PRODUCT CERTIFICATION TITLE: INSPECTION AND TESTING DOC: PC-9573 ISSUE: 01 PREPARED BY: DATE: NOV 2013 PAGE: 1 OF 4 APPROVED BY: SECTION 5: INSPECTION AND TESTING 5.1. Packaging material requirement The Rubber hoses may be packed as agreed to between the purchaser and the supplier. 5.2. List of test equipment/ facilities S. No. TEST EQUIPMENT L.C. AND RANGE CALIBRATION FREEQUENCY REF. CLAUSE OF IS 9573 Remarks 1 MDR 2000 Rheometer alongwith required software NA HALF YEARLY NA 1 NO. 2 Melting Point Apparatus 1 °C NA NA 1 NO. 3 Ageing oven 1 °C(0- 450) YEARLY 5.4.2, 5.5.7 2 NO. 4 Shore- A Hardness Tester 1 Shore A YEARLY NA 1 NO. 5 Muffle furnace 1°C(0-1200) YEARLY NA 1 NO. 6 Electronic balances 0.001gm(0210) YEARLY 5.4.3 1 NO. 7 pH Meter/ pH Paper 1 to 14 YEARLY NA 1 NO. 8 ID Gauge /Vernier caliper 0.02mm (0200) YEARLY 5.3.1 1 NO. 14 BUREAU OF INDIAN STANDARDS PRODUCT MANUAL PRODUCT CERTIFICATION TITLE: INSPECTION AND TESTING DOC: PC-9573 ISSUE: 01 PREPARED BY: DATE: NOV 2013 PAGE: 2 OF 4 APPROVED BY: 9 Dial Thickness Gauge 0.01mm(010) YEARLY 5.4.1 , 5.4.2 2 NO. 10 Flexibility test fixture NA NA 5.5.3 1NO. 11 Flame resistance test chamber NA NA 5.5.8 1 NO. 12 Ultra Low Freezer 0.1 °C(+70 to -40) 2 YEAR 5.5.2 1 NO. 13 Fixture for Grip Test along with Standard Weight(4.50kg) 4.5 Kgs YEARLY 5.5.7 1 NO. 14 Compression Moulding Press NA YEARLY ( Temp. controller 5.4.1 , 5.4.2 & Pressure gauge) 1 NO. 15 Slab Moulds . NA NA 5.4.1 , 5.4.2 1 NO. 16 Button Moulds NA NA NA 1 NO. 17 Constant Temp. Oil Bath 1 °C(0-250) YEARLY NA 1 NO. 18 Proof & Burst Testing Machine 290PSI, max (0-14000psi, max) YEARLY 5.5.5.1 , 5.5.5.2 2 NO. 15 BUREAU OF INDIAN STANDARDS PRODUCT MANUAL PRODUCT CERTIFICATION TITLE: INSPECTION AND TESTING DOC: PC-9573 ISSUE: 01 PREPARED BY: DATE: NOV 2013 PAGE: 3 OF 4 APPROVED BY: 19 Leakage Testing Machine 0.01Kg/cm2f (02.5Kg/cm2) YEARLY 5.5.7 1 NO. 20 Adhesion Testing Machine 0.25 Kg (030kg) YEARLY 5.5.1 1 NO. 21 Tensile testing Machine 0.1kg (0225) YEARLY 5.4.1 , 5.4.2, 5.5.1 1 NO. 22 Micrometer 0.01/0.001 mm(0-25) YEARLY 5.3.2 2 NO. 23 Steel Scale 1/0.5 mm(01000) YEARLY 1 NO. 5.3. Test facilities in BIS Labs/ OSLs with testing charges and approximate time The list of BIS laboratories and laboratories recognized by BIS, where sample can be sent for independent testing, are available on BIS intranet/website. The inspecting officer/agent shall collect latest status in respect of any laboratory before proceeding for inspection. 5.4. Basis of grant of licence The basis of grant of licence shall be based on satisfactory preliminary inspection and passing of drawn sample in independent testing. 16 BUREAU OF INDIAN STANDARDS PRODUCT MANUAL PRODUCT CERTIFICATION TITLE: INSPECTION AND TESTING DOC: PC-9573 ISSUE: 01 PREPARED BY: DATE: NOV 2013 PAGE: 4 OF 4 APPROVED BY: 5.5. Details of tests to be carried out in the factory Following tests may be carried out in factory: Cl. No. 5.3.1 5.3.2 5.3.2 5.4.1 5.4.1 5.4.1 5.4.1 5.5.1 5.5.3 5.5.5 5.5.5.1 5.5.5.1 5.5.5.2 5.5.7 5.5.8 TEST DESCRIPTION DIMENSIONS Bore Size Thickness Of Lining Thickness Of Cover PHYSICAL REQUIREMENTS Tensile Strength of Lining Tensile Strength of Cover Elongation at break of Lining Elongation at break of Cover ADHESION TEST Tube to Braid Braid To Cover FLEXIBILITY TEST HYDRAULIC TEST Proof Pressure Test Change in length at proof pressure Bursting Pressure Test Grip Strength Test Burning Behavior Test REMARKS One day One day One day One day One day One day One day One day One day One day One day One day One day One day One day 17 Annex 1 18
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