SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF COPPER ALLOY GATE, GLOBE AND CHECK VALVES FOR WATER WORKS PURPOSES ACCORDING TO IS 778:1984

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1 SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF ACCORDING TO DOC:STI/778/4 1 LABORATORY - A laboratory shall be maintained which shall be suitably equipped and staffed, where different tests given in the specification shall be carried out. 1.1 The testing equipment shall be periodically checked calibrated and records of all such checks calibrations shall be maintained. 1.2 TEST RECORD - The thread gauges shall be calibrated after every 5000 applications or one in three years whichever is earlier. 2. All records of tests shall be kept in suitable forms approved by the Institution. 2.1 Copies of any records or charts that may be required by the Institution shall be made available at any time on request. 2.2 It is recommended that, as far as possible, Statistical Quality Control (SQC) methods may be used for controlling quality during production as envisaged in this scheme {See IS 397 (Part 1)-1972, IS 397 (Part II) 1975) and IS 397 (Part III)-1980}. 3. MARK - The Standard Mark, as given in Column (1) of the first schedule of the licence shall be punched or cast on each valve, i.e. Gate valve, Globe Valve or Check Valve provided always that the valve thus marked conforms to every requirements of the specification. 4. In addition, each valve shall be cast or stamped on the body with the following information: a) Manufacturer s name or his recognized trade mark, b) Class, 1 or 2, as applicable; c) Nominal Size; d) An arrow showing direction of flow in the case of Globe Valves and Check Valves; e) Identification in code or otherwise to enable to trace back the date of casting to factory test records (may be stamped) and f) Made in India, if required. 4.1 The information relating to type of valve as given in cl. 5 of shall be supplied with the valves.

2 5. LEVELS OF CONTROL - The tests as indicated in Table 1 attached and at the levels of control specified therein shall be carried out on all raw materials components and the finished production on the whole production of the factory which is covered by this Scheme and appropriate records and charts maintained in accordance with paragraph 2 above. All the production which conforms to the Indian Standard and covered by this licence shall be marked with ISI Certification Mark. 6. MATERIALS -The material for component parts of valves shall conform to requirements given in Table 1 of. 6.1 Test Bars/samples and criteria for acceptance shall be as specified in relevant specification referred to in Table 1 of. 6.2 CHEMICAL COMPOSITION - One sample for each heat/melt of Ingots shall be tested for chemical analysis. In cast Ingots are received with suppliers test certificate, the testing may be restricted one sample in a quarter. From the castings one sample may be tested for chemical analysis for 1000 kg or part thereof of the castings. 6.3 TENSILE TEST Three tensile test pieces shall be separately cast, alongwith castings for every 1000 kg of castings. One piece should be tested for tensile test. If it passes, the lot of casting maybe accepted. In case of failure, two further test pieces representing the same lot of castings maybe tested in the same manner. If both pieces pass the lot may be accepted, otherwise rejected. 7 DESIGN AND MANUFACTURE - Design manufacture and dimensions of components parts including bolts, nuts and threads on stem and valves shall conform to requirements given in Column 7 and Column 8 and table 2 to 12 of. 7.1 Except Gates for Gate Valves all other essential parts which are subject to wear shall be interchangeable for the same size and type of valve of same manufacturer. 7.2 Bolts and nuts shall conform to IS 1367(Parts):1979/ Threads on the stem shall be of the square or trapezoidal form preferable conforming to IS 4694:1968, IS 7008(Part-III):1973 and IS 7008(Part-IV):1973, Stem of 8mm and 10mm size valves may have screw threads conforming to IS 4218(Part-III):1967 and IS 4218(Parts-IV): HYDROSTATIC TEST ON BODY AND SEATS - Each valve shall be tested for hydrostatic pressure test in accordance with clause 9.3 to 9.5 of. If any valve fails in this test, the valve should be rejected for the purpose of ISI Certification Mark. 9. In respect of all other clauses of the specification and at all stages of manufacture the factory shall maintain appropriate controls and checks to ensure that their product conforms to the various requirements of these clauses. 10. A record shall be maintained giving information regarding rejection of valves which do not conforms to the specification and method of their disposal. Such valves, shall in no case be stored with those conforming to the specification. 11. The licensee shall supply, free of charge, the samples required in accordance with the Bureau of Indian Standards (Certification) Regulations, from his factory or godown. BIS shall pay for the samples taken by it from the open market.

3 12. Whenever a complaint is received soon after the goods with the Standards Mark have been purchased and used, and if there is adequate evidence that the goods have not been misused, defective goods or their components shall be 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 conformity of the product to the Indian Standards shall be with the institution. 13. The marking of the product shall be stopped under intimation to the BIS 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, or if directed to do so by BIS for any reason. The marking may be resumed as soon as the defects are removed or when BIS gives the permission to do so. The information regarding resumption of marking shall also be sent to the institution. 14. The licensee shall send to the institution as per the enclosed proforma, a statement of quantity produced, marked and exported by him and the trade value thereof for each year of operation of the Licence. This statement should be sent twice a year, that is six months and one year after the grant/renewal of the Licence. Table 1...

4 TABLEL 1 LEVELS OF CONTROL (Para 5 to 9 of the Scheme of Testing and Inspection) Clause. 6.1 & Table 1 TEST DETAILS Requirements Test Method Clause Reference Materials No. of Samples i) Cast Iron IS 210:1978 One b) Tensile Test 3 Tensile Bars c) Hardness Test 3 Hardness Test ii) Extruded/High Tensile/Forged Brass iii) Leaded Tin Bronze/Brass Ingots IS 3488:1966 IS 319:1974 IS 320:1980 IS 6912:1973 IS 318:1981 IS 1264:1981 pieces Adequate number of samples to be drawn and tested One b) Tensile Test 3 Tensile Bars LEVELS OF CONTROL Frequency Each Melt/ Heat of 1000 kg. or part thereof Each consignment Each Heat/Melt of 1000 kg or part thereof REMARKS See cl.6.2 of STI. See cl. 6.3 of STI. If a test certificate indicating conformity to the requirements is obtained, testing by licensee maybe restricted to once in three months as counter checks. In cast a test certificate indicating conformity of the ingots to specification is received, counter checking may be done only once in three months as counter checks. In case test certificate is not available, the level of control shown should be followed. See also clause 6.2 & 6.3 of STI iv) Chromium IS 4389:1972 Steel One -do- -dob) Tensile Test 3 Tensile Bars c) Hardness Test 3 Hardness Test pieces

5 TABLEL 1 LEVELS OF CONTROL (Para 5 to 9 of the Scheme of Testing and Inspection) DOC:STI/778/4 Clause 7 & TEST DETAILS Requirements Test Method Clause Reference IS 2712:1971 v) Gasket vi) Gland packing Weight/Size Design, manufacture and dimensions and workmanship: Valve bodies bonnets stuffing box, Gland, Body seat, stem, Wedge Disc assembly (For Globe valves), Disc (For check valves) back seat, Handwheel Body, Test (Hydrostatic) 9.4 Back seat test 9.5 Seat test (Hydrostatic) 12 Preparation/dispatch Cl.7 & 8 Tables 2 to & Table & table & Table to 12.4 IS 5414:1969 IS 4687:1980 -do- -do- No. of Samples Three LEVELS OF CONTROL Frequency Each consignment -do- Gauges (Go, No- Go Plug, Snap, thread) templates, micrometers, vernier calipers, depth gauge etc. and visual examination. Each component All Each Valve REMARKS If a test certificate indicating conformity to the requirement is obtained testing by licensee may be restricted to thrice in a year as counter check. Refer Cl.7 of STI

2. 0 Test Records - All records of analysis and tests shall be kept in suitable forms approved by the Bureau of Indian Standards.

2. 0 Test Records - All records of analysis and tests shall be kept in suitable forms approved by the Bureau of Indian Standards. SCHEME OF TESTING AND INSPECTION FOR CERIFICATION OF LABORATORY GLASSWARE GRADUATED MEASURING CYLINDERS ACCORDING TO IS 878:2008/ISO 4788:2005 (Second Revision) DOC: STI/878/2 1.0 Laboratory - A laboratory