7 The revised IS 8034:2002 and revised STI be implemented w.e.f. 1 Feb 2005.

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1 BUREAU OF INDIAN STANDARDS (CENTRAL MARKS DEPARTMENT-III) Our Ref: CMD-III/16: Oct 2004 Subject: Implementation of revised IS 8034:2002 Submersible Pump Sets and revised STI (Doc:STI/8034/5 ) IS 8034:1989 has been revised and published as IS 8034:2002. Subsequently, Amendment No. 1 to IS 8034:2002 has also been published to take care of printing error. In the revision of IS 8034, following changes have been made: 5 All the five amendments issued to IS 8034:1989 have been incorporated. ii) Terminology of static water depth, draw down and submergence have been modified. iii) Some of the construction features have also been modified in line with the prevailing manufacturing practices. iv) Minimum efficiency has been increased by 5% over the existing pump efficiency and correspondingly the minimum overall efficiency would increase depending upon the motor rating. Accordingly minimum efficiency graphs given in Fig. 4 & Fig 5 have been modified The concept of nominal rating for the duty point has been introduced in this revision. On this nominal rating, specified tolerances may be made applicable so that there is no need to test the pump again at user s required duty point which fall within the tolerance and may be certified as such provided the pump meets all other requirements of standard at the user s required duty point. However, it would be desirable and more useful to apprise the user that certified pump at user s required duty point may conveniently be used, if within the specified tolerance of nominal duty and meeting other performance characteristics at user s required duty point rather than certifying the same pump again at user s required duty point. Referred testing standard IS 11346:1985 has also been revised and published as IS 11346:2002 and pumps are required to be tested as per revised specification. Consequent upon revision of IS 8034, STI has been revised as Doc:STI/8034/5 Aug 2004 (copy enclosed). While finalizing the STI, the recommendations of seminar on implementation of revised pump standards organized at Coimbatore in March 2004 have been considered. The changes in revised STI and the methodology for changeover was discussed and explained to the participants in the All India Seminar of Submersible Pump Sets organized at Ahmedabad on 21 Sep The licensees are required to examine the duty point of various models of pumps covered in their licence and re-declare the same wherever required in view of increased minimum efficiency in the revision. In view of changes to be incorporated by licensees in the design of the pumps for achieving higher efficiency, testing of the samples is required as per revised declaration wherever required, before endorsing the same in the licence as a result of implementation of revised IS 8034:2002. It is proposed that : 7 The revised IS 8034:2002 and revised STI be implemented w.e.f. 1 Feb BOs to inform the licensees under their jurisdiction about implementation of revised IS 8034:2002 and STI. 9 Licensees to re-examine declaration of duty point for various size of pumps covered in the licence and re-declare duty point wherever required due to increased minimum efficiency. The licensees shall also be asked to specifically declare the design changes made in the pump and/or motor to achieve the revised overall efficiency requirements. 10 In case the declared overall efficiency of a particular pump is already exceeding the revised minimum efficiency requirements, such pumps need not be subjected to any retesting and no fresh endorsement is required in the licence for this purpose. 11 In case where the declared overall efficiency was lower than the revised minimum efficiency, but the last independent test report indicates that the revised overall efficiency has been achieved at duty point, such pumps may not be taken up for retesting and endorsement may be made in the licence based on re-declared duty point. A clear undertaking be taken from the licensee that the design of the pumps shall ensure meeting the revised efficiency requirements on consistent basis. However, if the licensee proposes any design change in such pumps they should be taken up for classification and testing as per Annex I.

2 12 For all other cases, where the pumps were having overall efficiency lower than the required minimum efficiency, the licensee shall declare the design changes for each model. These pumps are required to be tested as per the sampling plan given in enclosed Annex I for re-declared duty point to cover the entire range of pumps already covered in the existing licence. In the revised version, there is no change in the performance requirements for the motors. Therefore, only performance of the pump sets to be verified for changeover. However, if the licensee has made design changes in the motors to achieve overall efficiency required, then verification of the motors is also required. The licensee is required to submit the test reports of the samples tested in the factory as per re-declared parameters (drawn as per Annex I) and to offer these samples for testing in independent laboratory. Based on the verification of the test reports submitted by the licensee, necessary endorsement be made in the licence for changeover to revise IS 8034:2002. The licensees should be informed that in case samples tested in independent laboratory are found not conforming to the declared parameters, BIS shall issue stop marking of those group of pumps which are represented by the samples found not conforming. The licensee may re-offer the sample within one month and in case the sample is not re-offered for independent testing or the second sample also fails, the corresponding varieties shall be deleted from the licence. Licensees are required to pay special inspection charges for the visit and testing charges for testing of samples in independent labs wherever applicable. 13 All pending applications where samples have already been drawn, applicants may be given option to re-declare the duty point and samples may be tested accordingly. In those cases, where test reports have been received as per IS 8034:1989 and either the applicant has not declared the revised duty point or the sample is not conforming to the re-declared duty point, licence may be granted as per earlier declaration as per IS 8034:1989 after taking an undertaking that firm will ensure implementation of revised IS 8034:2002 and revised STI by stipulated date as per the provision given in d) above. In all other cases, pending applications be processed as per IS 8034: BOs may advise the licensees that no extension will be given in the implementation date and in those cases where licensee failed to offer sample(s) by stipulated date, stop marking instructions will be issued and w.e.f. 1 Feb 2005 certification of submersible pump sets will be as per IS 8034:2002 only. Submitted for approval please. Sd/- (C.K. Veda) DCM-III DDGM - Sd/- Circulated to All ROs/BOs/BIS Labs/CMD-I/MED- for information and necessary action.

3 SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF SUBMERSIBLE PUMPSETS ACCORDING TO IS 8034:2002 (Second Revision) (Incorporating Amendment No.1) DOC:STI/8034/5 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 in accordance with the methods given in the specification. 2. TEST RECORDS - All records of tests, inspection and calibration shall be kept in suitable 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 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, Statistical Quality 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):1972, IS 397(Part 2):1985 and IS 397(Part 3):1980]. 3.1 In addition, effort should be made to gradually introduce a Quality Management System in accordance with IS/ISO 9001 as appropriate to the activities of the organization. 4.0 STANDARD MARK The Standard Mark, as given in Column (1) of the First Schedule of the licence, shall be applied on the name plate of each pump, provided always that each pump, so marked conforms to every requirement of the specification. 5.0 OTHER MARKING : In addition the following information shall be furnished on the name plate affixed to the pumpset: 5 Manufacturer s name or trade mark (if any) 6 Model, 7 Serial No.; 8 Number of stages; 9 Bore size, Min; 10 Head, at nominal duty point; 11 Discharge, at nominal duty point; 12 Overall efficiency; 13 Motor rating (kw); 14 Rated speed (rpm); 15 Maximum current (amp); 16 Rated voltage (v) with variation; 17 Rated frequency (Hz); 18 Connection star/delta; 19 Type of duty (whether continuous or not); 20 Delivery size; 21 Head range for non-overloading requirements; and 22 Licence number (CM/L.).

4 DOC:STI/8034/5 6.0 LEVELS OF CONTROL - The tests, as indicated in Table 1 and 2 attached and at the levels 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. 7.0 In respect of all other clauses of the specification the factory will maintain appropriate control and checks to ensure that their product conforms to the various requirements of this specification. 8.0 RAW MATERIALS - It is recommended that, as far as possible, each consignment of the raw material should be accompanied by a test certificate certifying its conformity to the relevant Indian Standard. 9.0 REJECTIONS A separate record shall be maintained giving information relating 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 SAMPLES The licensee shall supply, free of charge, the samples required in accordance 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 REPLACEMENT Whenever a complaint is received soon after the goods with Standard 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 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 STOP MARKING The marking of the product shall be stopped under intimation 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 to Bureau 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 PRODUCTION DATA The licensee shall send to BIS as per the enclosed proforma-1 to be authenticated by a Chartered Accountant or by the manufacturer by giving an affidavit/undertaking, a statement of quantity produced, marked and exported by him and the trade value thereof at the end of each operative year of the licence. Table 1

5 IS 9283:1995 MOTORS FOR SUBMERSIBLE PUMPSETS TABLE 1 LEVELS OF CONTROL (Para 6.0 of the Scheme of Testing and Inspection) DOC:STI/8034/5 TEST DETAILS Cl. Requirement Test Methods No. of samples Clause Reference 5 General 5.1 to IS 9283 Each motor Construction 5.3 Earthing 5.4 Finish of Bearings Balancing of Rotor 11.1 & IS & IS (Pt.1) 7.0 Dimensions 7.1 & Table Shaft 4. Extension run IS 2223 out, concentricity of mounting, mabbet and face run out 13 Terminal markings 16.2 (a) Insulation resistance before & after HV test 16.2 (b) High Voltage Test 16.2 (c) No load running of Motor and reading of current and voltage 16.2 (d) Locked rotor reading of Voltage, Current and Power input One Rotor/shaft /sleeve Each Rotor One Motor One Rotor Shaft 13 IS 9283 Each motor & IS or IS IS IS 7572 LEVELS OF CONTROL Lot Size Frequency Remarks One sample per week One sample per day

6 DOC:STI/8034/5 TEST DETAILS Cl. Requirement Test Methods 16.2 (e) Reduced voltage running up test at no-load (for 3 phase motors only) 16.1 (p) Leakage Current Test at rated voltage 16.1 (c) Measurement of Stator Resistance 16.1 (g) Full Load Reading of voltage, Current Power input and Slip 16.1 (h) Performance characteristics 16.1 (f) Locked rotor torque IS 9283:1995 MOTORS FOR SUBMERSIBLE PUMPSETS TABLE 1 LEVELS OF CONTROL (Para 6.0 of the Scheme of Testing and Inspection) No. of samples Clause Reference 16.2 (e) IS 9283 Each motor 23 One out of every 10 or less motors of identical type and design produced in a month. 6 IS 4029 or 7 IS IS 4029: or 8.4 IS & IS 9283 Table 2 a) IS 4029 or 8.2 IS 7552 One Motor LEVELS OF CONTROL Lot Size Frequency Remarks One out of every 50 or less motors of identical type and design produced in a month.

7 DOC:STI/8034/5 IS 9283:1995 MOTORS FOR SUBMERSIBLE PUMPSETS TABLE 1 LEVELS OF CONTROL (Para 6.0 of the Scheme of Testing and Inspection) TEST DETAILS Cl. Requirement Test Methods 16.1 (m) 16.1 (n) Momentary Overload Test Vibration Test No. Of samples Clause Reference 18 IS 9283 As per agreement with purchaser LEVELS OF CONTROL Lot Size Frequency Remarks See Note 3 Note 1 The tests given in Table 1 are applicable when motor is manufactured in house. If motor is bought out item and each consignment is accompanied by a test certificate indicating values as per IS 9283 or BIS certified tests as per Table 1 not required. Note 2 For performance other than at rated voltage, the performance values shall be checked as per the guidance given in note 3 under cl.17 of IS Note 3 Momentary overload and vibration test shall be carried out as per the mutual agreement with the purchaser.

8 Cl. IS 8034:2002 SUBMERSIBLE PUMPSETS TABLE 2 LEVELS OF CONTROL (Para 6.0 of the Scheme of Testing and Inspection) TEST DETAILS Requiremen Test Methods t Clause Reference 6.2 Material of construction of various parts (Mechanical test) Impeller balancing Pump shaft or protecting sleeve surface finish 9.1 Hydrostatic Test 11.2 Maximum Outside Diameter of submersible pump set Temperatur e rise Test at rated voltage Temperatur e rise test at reduced voltage 14.1 Pump Test and Verification of No. of samples 6.2 IS 8034: Each melt of various parts DOC:STI/8034/5 LEVELS OF CONTROL Lot Size Frequency Remarks The parts should conform to the relevant specifications as given in Cl.6.2 of IS 8034: Each impeller This is applicable for metallic impeller only One One sample per week 9.1 Each pump set This test to be carried out on individual casing part of pump as a 11.2 One One sample per day 15 One One out of every 50 pumpsets or less of indentical type & size produced in a month One whole assembled condition. 8 IS One In case of failure all the pumps shall be tested till five consecutive samples pass. Guarantees Note : In case of pump set, motor shall be tested for all routine tests as per cl.16.2 of Is 9283:1995 and type tests except full load test (16.1 (g)), performance characteristics (16.1 (h)), momentory overload (16.1 (m), and vibration test (16.1 (n) as per the frequency given in Table 1 of this STI. in