CENTRAL MARKS DEPARTMENT-II (Legal) Our Ref: CMD-II(L)/6:899 Subject: Implementation of IS 899:0 Liquefied Petroleum Gas (LPG) Containers for Automotive use - Specification (First Revision) The revision of IS 899:000 as IS 899:0 had been informed to all RO/BOs vide our note no. CMD-II/6:899 dated 09 0 (hosted on Intranet on 6 09 0)which will come in force with effect from 8. Vide above note, VZBO was requested to prepare the STI and the switchover guidelines as per revised IS 899:0, being the custodian BO. Thereafter all RO/BOs were advised to make follow up action and send comments/difficulties if any if expressed by the licensees/applicants to VZBO for finalization of revised STI and the guidelines for implementation of revised standard vide our note dated 9 0 0( hosted on Intranet on 0 0 0). Subsequently, the draft STI as DOC:STI/899/ Jan 0 as per IS 899:0 has been circulated to all RO/BOs by SRO on 8 0 0. Vide their mail, all RO/BOs were requested to send their comments if any on the draft STI to SRO by 0 0 0. The revised STI, and the switchover guidelines for revised IS 899:0 are enclosed for forwarding to all licensees and applicants under their jurisdiction. All RO/BO/SBOs are requested to initiate the action for implementation of revised IS 899:0 as per the enclosed guidelines on priority so that the same can be completed by its specified date. This is issued with the approval of the Competent Authority. (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 (VZBO) : Head (MED)
SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF LIQUIFIED PETROLEUM GAS (LPG) CONTAINERS FOR AUTOMOTIVE USE ACCORDING TO IS 899:0. 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.. CALIBRATION: All testing apparatus/measuring instruments shall be periodically checked and calibrated and records of such checks/calibration shall be maintained... The frequency of calibration of the following instruments shall be as under; i) ii) iii) iv) v) vi) vii) viii) ix) Universal Testing Machine- once in a year Pressure Gauges: Once a month by own dead-weight pressure gauge tester or from outside laboratory. Pyrometer or temperature measuring device fitted to furnace: once in six months. Hardness tester- As specified by the manufacturer with the reference material supplied by the manufacturer Scale/Depth guage: once in three months. Plug guage; once in six months. Ultrasonic thickness guage: once in six months. Paint thickness measurement guage: once in six months. Weighing Balance: once in six months. For all other instruments, frequency of calibration shall be once a year. Calibration shall be done from NABL accredited 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. The manufacturer shall maintain a Quality Assurance department and shall enforce proper inspection at all stages of manufacturing as per the schedule at Annex A to ensure that each is free from any manufacturing defects and comply in all respects to Indian Standard Specification..0 TEST RECORDS. All records of tests and inspection shall be kept as shown in Annex A to Annex D.. Copies of any record and other related papers that may be required by the Bureau shall be made available at any time on request. Page of 8
. The Bureau, shall have free access at all reasonable time to any part of the manufacturers works and shall also be at liberty to inspect the fabrication at any stage and to reject any or part of a that does not comply with the requirements of this standard.. The manufacturer shall supply the labour and appliances for such inspection and tests as are required and for any additional checks desired by the Bureau..0 TEST CERTIFICATE:. A certificate as shown in Annex B shall be issued by the BIS Inspecting Officer in respect of every lot/batch of cylinders marked with BIS Standard Mark at the time of giving dispatch clearance.. The certificate shall be issued by the inspecting officer in respect of every batch of s marked with BIS standard mark at the time of despatch clearance. Full composition/chemical analysis of the cast as given in the steel supplier test certificate shall be reproduced in the test certificate issued for release of s. The period for test certificate issued shall be taken from the date of release of steel to the date of final pneumatic test..0 QUALITY CONTROL:. The manufacturer shall maintain a Quality Assurance department and shall enforce proper inspection at all stages of manufacturing as per the schedule at Annexure. A to ensure that each is free from any manufacturing defects and comply in all respects to Indian Standard Specification.. It is recommended that as far as possible Statistical Quality Control (SQC) methods may be used for controlling the Quality during production as envisaged in the scheme (See IS 97 (PartI), IS 97 (Part-) and IS 97 (Part-).. In addition, effort should be made to gradually introduce a Quality Management in accordance with the Quality System Modules as per IS/ISO 900 or IS/ISO 900 or IS/ISO 900 as appropriate to the activities of the organization..0 STANDARD MARK: The Standard Mark, as given in Column () of the licence, shall be Stamped on a non detachable and non pressure part of the provided always that each so marked conforms to every requirement of the specification.. OTHER MARKING: shall bear a plate permanently attached with the following data clearly and legibly and records maintained as per Table of Annex C: Page of 8
a) b) c) d) e) f) g) h) i) j) k) m) n) p) A unique serial number; The minimum/nominal water capacity in litres; Tare weight (excluding fittings) in kg; The marking : LPG (Liquified Petroleum Gas) ; Test pressure in MPa ; The wording ; Maximum degree of filling 80 per cent ; Year and month of testing ; Approval mark of inspection authority; with Licence number CM/L-. Name and trade mark of the manufacture ; IS number ; Enough space for re-qualification mark ; Licence number (CM/L No..) ; Maximum working pressure in MPa; in Diameter (for cylindrical or height for special for width & length) q) The s shall carry an orientation mark to install the in correct position. 6.0 MATERIAL: These shall be as follows: a) Stress resistant shells shall conform to IS 60 or IS 9 b) Stainless steel, if used shall conform to chemical composition and mechanical properties as given in Clause. of IS 899: 0. c) If Low carbon steel or stainless steel other than above are used, then prior permission of Statutory Authority to be obtained and shall meet the provisions of clause.. of IS 899: 0. d) Powder coating as per IS 87 e) Multi function valve fitted with the shall conform to IS 00 or if any other multi functional valve assembly is used, it shall be approved by the Statutory Authority and shall contain the accessories as per Clause of IS 899: 0. 7.0 DOCUMENTATION TO BE SUBMITTED: The following documents shall be made available to the Inspecting Officer: i) Document showing approval of Statutory Authority as per clause.. of IS 899: 0 ii) Chemical cast analysis certificates as per clause.. of IS 899: 0 iii) Document showing the approval of Statutory Authority as per clause of IS 899: 0 iv) Document showing the approval of Statutory Authority as per clause 6.. of IS 899: 0 v) Document showing the approval of Statutory Authority as per clause 6... of IS 899: 0 vi) Document showing the approval of Statutory Authority as per clause 8.. of IS 899: 0 Page of 8
vii) Document showing the approval of Statutory Authority as per clause of IS 899: 0 viii) Document describing the welding methods, processes used and inspections carried out during production. ix) Document showing approval of Statutory Authority if any other multi function valve assembly is used as per Clause of IS 899: 0. 8.0 BATCH: 8. For the purpose of this Scheme 0 s or less of identical type and design heat treated during one continuous running in the same manner and under similar conditions and constructed from steel of similar analysis and made by the same steel manufacturer shall constitute one batch. 8. The identity of each batch shall be separately maintained. 9.0 DESIGN: The design of Liquefied Petroleum Gas Containers for Automotive Use shall be as per Clause 6 of IS 899: 0. 0. CONSTRUCTION AND WORKMANSHIP: 0. General Requirements: The General requirements of Liquefied Petroleum Gas Containers for Automotive Use shall be as per clause 7. of IS 899: 0 and records maintained as per Table of Annex C. 0. Parts Subjected to Pressure: 0.. Welding Requirements: The welding requirements of Liquefied Petroleum Gas Containers for Automotive Use shall be as per clause 7.. of IS 899: 0 and records maintained as per Table A of Annex C. 0.. Welds Joining Parts: The welds joining parts of Liquefied Petroleum Gas Containers for Automotive Use shall be as per clause 7.. of IS 899: 0 and records maintained as per Table B of Annex C. 0.. Inspection of Welds: The Inspection of welds of Liquefied Petroleum Gas Containers for Automotive Use shall be as per clause 7.. of IS 899: 0 and records maintained as per Table C of Annex C. 0. Out-of- Roundness The Out-of Roundness of Liquefied Petroleum Gas Containers for Automotive Use shall be as per clause 7. of IS 899: 0 and records maintained as per Table of Annex C. Page of 8
. FITTINGS: The Fittings of Liquefied Petroleum Gas Containers for Automotive Use shall be as per clause 8 of IS 899: 0 and records maintained as per Table of Annex C.. HEAT TREATMENT:. After completion of all inspections satisfactory the s shall be punched with serial number before putting them into the furnace for heat treatment.. All s shall be normalized or stress relieved as per clause 9 of IS 899:000 and records maintained as per Table of Annex C. TESTS:.. The tests shall be carried out under the supervision of an inspecting officer of the Bureau and the s marked with BIS standard mark... The preparation and testing of test specimen shall be done as per clauses 0. to 0. of IS 899:0... All pressings and shells shall be examined for surface defects before any welding. No pressing or shell having defects beyond the acceptable limits shall be used... Should any pressing or shell be of thickness less than the minimum specified thickness the whole output from the relevant batch of material shall be examined for minimum thickness and any pressing or shell which is less than the specified minimum thickness shall be rejected and deshaped by pressing... Mechanical tests: The Mechanical tests shall be carried out as per Clause 0. of IS 899: 0 and records maintained as per Table 6 of Annex C...6 Permenant Stretch Test and Burst test under Hydraulic Pressure These tests shall be carried out as per Clause 0. of IS 899: 0 and records maintained as per Table 7 of Annex C...7 Hydrostatic test and Pneumatic test These tests shall be carried out as per Clause 0. and 0. of IS 899: 0 and records maintained as per Table 8 of Annex C...8 Non- Destructive Examination These tests shall be carried out as per clause 0. of IS 899: 0 and records maintained as per Table 9 of Annex C. Page of 8
TYPE TEST :. All the type tests as per clause 0.6 of IS 899:0 have to be carried out in case of change in the design parameters or change in the manufacturing process of s and records maintained as per Table 0 of Annex C.. All the type tests except strength assessment test shall be repeated on each design/size once in every three years. The strength assessment test shall carried out every year. In case of failure the design shall be modified after investigation and corrective actions shall be verified by BIS before manufacturing of s.. SURFACE COATING AND COLOUR: The Surface Coating and Colour shall be as per clause of 899:0 and records maintained as per Table of Annex C. 6. TECHNICAL REQUIREMENTS FOR TYPE APPROVAL: The Technical Requirements for Type Approval of Liquefied Petroleum Gas Containers for Automotive Use shall be as per clause of IS 899: 0. 7. ACCESSORIES: The accessories that shall be fitted on Liquefied Petroleum Gas Containers for Automotive Use shall be as per clause of IS 899: 0 and records maintained as per Table of Annex C. 8. LEVELS OF CONTROL: The tests as indicated in Table of Annex D and at the levels of control specified therein, shall be carried out on the whole production covered under this scheme and appropriate records and charts maintained in accordance with paragraph above. On the basis of test results decision regarding conformity or otherwise of the control unit shall be taken. All the production, which conforms to the Indian Standard and covered by the licence shall be marked with Certification Mark of the Bureau. 9. 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. 0. SAMPLES The licensee shall supply, free of charge to the Bureau and to its authorized representatives, the sample required in accordance with the Bureau of Indian Standard (Certification) Regulations, from his factory or godown as and when required by the Bureau. BIS shall pay for the samples taken from the market. Page 6 of 8
. REPLACEMENT Whenever a complaint is received soon after the goods with the Standard Mark have been purchased and used, and if there is adequate evidence that the goods have not been misused, defective goods shall be replaced, 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 Standard shall be with Bureau. The firm shall have own complaint investigation system as per IS/ISO 000. In the event of any damages caused by the goods bearing the Standard Mark, or claim being filed by the consumer against BIS Standard Mark and not confirming to the relevant Indian Standard, entire liability arising out of such non confirming product shall be of the 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 difficulty in maintaining the conformity of the product to the specification or the testing equipment goes out of order. The marking shall also be stopped immediately if directed to do so by the Bureau for any reason. The marking may be resumed as soon as the defects are removed or when the Bureau gives the permission to do so. The information regarding the date of resumption of marking shall be sent to the Bureau.. PRODUCTION DATA The licensee shall send to the Bureau as per the enclosed proforma, a statement of the quantity produced, marked and exported by him and the trade value thereof for every quarter of the operating period of the licence. The statement is required to be forwarded to BIS at the end of every quarter of operative period.. Table Page 7 of 8
ANNEX - A Stage inspection for manufacture of LPG s for Automotive use. Raw Material a) Check test for physical and chemical properties for each heat before use. b) Check for dimensions and surface defects (visual). c) Components material to be checked for chemical properties.. Manufacture of components : Body Components Check pressing and shell for Thickness and surface defects Such as cracks and laminations. Check dimensions and surface defects. Check of height to maintain Water capacity. Random check for data stamped. Stage wise records shall be maintained as per Annex C. Assembly and manufacture : a) b) c) d) e) f) g) h). Check top and bottom dished ends and the shell for defects and traces of oil. Inspect tack welding of backing strip if provided. Inspect welding defects of the body and components. Select s for hardness test, radiographic examination, acceptance test, bursting test and water capacity and hydrostatic stretch test. Check for defect after hydraulic test and pneumatic test. Check for Quality of protective metal coating, finishing and painting. Check valve pad threads, leakage between valve and valve pad and leakage of the (Pneumatically). Check weight and details stamped on the. Type tests : Select s for type tests viz., Bonfire test, Fatigue test, Crash test and Strength essential (as applicable ) for each design out of a batch of at least 0 s. Records shall be maintained as per Table 0 of Annex C. Page 8 of 8
IS 899 ISI ANNEX- B BUREAU OF INDIAN STANDARDS (.Branch Office) Serial TEST CERTIFICATE (FOR LPG CONTAINERS FOR AUTOMOTIVE USE) Certificate Ref : Date : Place : Licencee.. CM/L.Valid upto.. Purchaser Desitination.. Order No..Date. Container Description.Litres water capacity Two/three piece ID Length.Neck thread : IS. Maximum Working poressure MPa. Test pressure MPa. Number Serial Nos. to. This is to certify that the continers manufactured, inspected and tested under the supervision of BIS inspecting officer (s) during the periods from. to. at M/s meet the requirements of IS 899:000 and Drawing No. approved by the Chief Controller of Explosives, Govt. of India. The Containers have been fitted/not fitted with approved Valves. MANUFACTURING DETAILS Mfrs. Identification mark : Welding process : Submerged arc welding (at.. for minutes ) Method of support : Backing strip/joggling Steel used, Mfrs. Cast No TC No. Min. design thickness mm TESTS Hydrostatic test at MPa Pneumatic test at MPa Burst test (as per details below) Results ACCEPTANCE TESTS. of Continers tested.. Observed Values Min. Max. Pass Yield strength MPa Tensile strength MPa : Vicker s Hardness(HV) : % Elongation : Bend test (Face & Root) : (Circumferential & Longitudinal) Macro exam (Neck and Satisfactory Circumferential & Longitudinal for Body) Minimum Thickness..mm : RADIOGRAPHIC EXAMINATION of Containers tested : Page 9 of 8
Container No Hoop stress (MPa) Burst Pressure (MPa)...Permanent stretch (%). Container Nos..to of.batch covered under this certificate with and are reprsented by Acceptance test of Container No and burst test of Container No.. of.batch. These have been heat-treated in the same manner and manufactured from steel of similar analysis and of the same manufacture. QUANTITY INSPECTED : Container Nos. from.to SERIAL NO. OF REJECTED CONTAINERS. TOTAL NO. OF CONTAINERS PASSED.. Name & Designation of the Name and designation of inspecting officer Officer representing the manufacturer Bureau of Indian standards.. Page 0 of 8
ANNEX C STAGE INSPECTION FOR MANUFACTURE OF LPG CONTAINERS FOR AUTOMOTIVE USE Table - Record of General Requirements of Construction and Workmanship as per Clause 7. of IS 899: 0. (Clause 0. of STI) Name of testing person: Date of testing Whether parent Approved Observed Deviation observed Whether / plates and pressed dimension dimension of conforming parts used are free of the the contour of from defects contour of dished end the dished end Radial dimensions Axial dimension 6 7 8 Table A- Record of Construction and Workmanship for Parts subjected to Pressure- Welding Requirements as per Clause 7.. of IS 899: 0. (Clause 0.. of STI) Name of Welder: Qualification of welder: Details of Approval tests passed: Whether butt weld / executed by automatic welding process Location of butt welds on the stress resistant shell Whether there is superimposition of filler welds on butt welds/ if not the spacing between them Whether MIG or TIG welding with argon as inert gas employed (in case of stainless steel s) Whether conforming 6 7 Table B- Record of Construction and Workmanship for Parts subjected to Pressure- Welds joining parts as per Clause 7.. of IS 899: 0. (Clause 0.. of STI) Name of Welder: Qualification of welder: Details of Approval tests passed: / Longitudinal weld Whether weld executed in the form of a butt weld on the full section of the material Circumferential welds Rotation of longitudinal welds of pieces in the ends of longitudinal welds on any shell section 6 Whether weld executed in the form of a butt weld on the full section of the material 7 Whether conforming Whether weld of studded valve plate is as per Annex E Type of weld fixing the collar or supports to the Type of weld in welded mounting supports(if provided) Gra itational force required to withstand vibration, braking actions Misalignment of joint faces in case of butt welds 8 9 0 Page of 8
Table C- Record of Construction and Workmanship for Parts subjected to Pressure- Inspection of welds as per Clause 7.. of IS 899: 0. (Clause 0.. of STI) Name of Welder: Qualification of welder: Details of Approval tests passed: Conformity Frequency and extent of radiographic / to 7... examination: conformity to 7... 7... 7... 7... 6 Treatment of imperfection disclosed by radiographic examination 8 7 Whether deemed unacceptable Whether conforming 9 0 Table - Record of Out-of-Roundness as per Clause 7. of IS 899: 0 (Clause 0. of STI) /sl. / Out of roundness value Whether conforming Table - Record of Fittings as per Clause 8 of IS 899: 0 (Clause of STI) General Fittings Openings 8.. 8.. 8.. 8.. 8.. 8..6 8..7 a b c d e f g h 8.. 8.. 6 7 8 9 0 6 7 8 9 Table - Record of Cylinders subjected to Heat treatment as per Clause 9 of IS 899: 0. (Clause. of STI) Approval of Statutory Authority: Stress relieving temperature: Duration in minutes: Name of Operator: Date: Shift: Date of heat treatment Time in Time out /Quantity/ Nos. from and to () () () () no./sl. Table 6- Record of Mechanical tests as per Clause 0. of IS 899: 0. (Clause.. of STI) Tensile tests Hardness Bend test Macroscopic retesting Checking test examination Tensile Bend for water On On welds capacity parent test test metal 6 7 8 9 0 0 () Whether conforming Page of 8
Table 7- Record of Permanent Stretch test and Burst Test as per Clause 0. of IS 899: 0. (Clause..6 of STI) /sl. Hydrostatic stretch test Burst test Whether conforming Table 8- Record of Hydrostatic test and Pneumatic test as per Clause 0. and 0. of IS 899: 0. (Clause..7 of STI) /sl., Hydrostatic test Pneumatic test Whether conforming Table 9- Record of Non-destructive Examination as per Clause 0. of IS 899: 0. (Clause..8 of STI) no./sl.no. Radiographic examination Defects Defects for wall thickness mm Defects for wall thickness mm 6 Examination of outside surface of weld Whether conforming 7 8 Table 0- Record of type tests as per Clause 0.6 of IS 899: 0. (Clause. of STI) No / Bonfire test Fatigue test Crash test Strength assessment 6 Whether conforming 7 Table - Record of Surface coating and Colour as per Clause of IS 899: 0. (Clause of STI) / Minimum thickness of synthetic enamel paint Colour scheme as specified by the Statutory Authority Whether conforming Table - Record of Marking as per Clause of IS 899: 0. (Clause. of STI) No. Batc h no,/s l. A unique Minimu m/ nominal water capacity in litres Tare weight (excludin g fittings) in Kg Markin g of LPG Test pressure in MPa Wording: maximu m degree of filling 80 % Year and month of testing Standa rd mark 6 7 8 9 0 No / No Name and trade mark of the manuf acturer Specifi cation numbe r Space for requali ficatio n mark Table - Record of Accessories as per clause of IS 899: 0 (clause of STI) Multifunc 80% stop Level Pressure Remotely Gastional valve indicator relief valve controlled tight valve services housing assembly valve with excess flow valve 6 7 8 Max Wor king press ure in MPa Dia/heig ht/ width and length Orientation mark 6 Power supply bushing Non return valve Pressure relief valve 9 0 Page of 8
ANNEX D TABLE - LEVELS OF CONTROL (Clause 8 of the STI) TEST DETAILS Clause Requirement. Material : a) Steel sheets for shell and dished end. i) Chemical composition and physical properties ii) Thickness iii). 7. 7. 7. 7.. 7.. 7.. LEVELS OF CONTROL Test Methods Clause Reference of samples Lot Size. & IS 899.. heat of material received sheet Surface defects. b) Components Compatibility of components. Construction and workmanship General requirements 7.. (Table of Annex C) to 7.. Parts subjected to Pressure Welding requirements Welds joining parts making up the shell of the Inspection of welds(table A and Table B) Frequency 7... to 7... 7... to 7...7 7...& 0.. do- Remarks These tests shall be carried out only if found necessary by the Inspecting Authority. If material is ISI marked no testing is required. Both sides of sheet to be checked. consignment TC of the supplier/tr of independent Lab for each component, shall indicate compatibility. may be checked by gauging. Records are to be maintained for the first five pieces whenever production starts for each batch or whenever there is change in tool or its setting. All welds shall be throughly examiuned visually for any defects like blow holes, pin holes, under cuts, incomplete penetration etc. and records for inspection shall be maintained. Page of 8
TEST DETAILS Clause 7. Requirement LEVELS OF CONTROL Test Methods Clause Reference of samples Radiographic Examination (Table C of Annex C) 7..., IS 899 0.. to 0.. As given in Remark s Treatment of imperfections (Table C of Annex C) 7... Out of roundness 7. (Table of Annex C) 8. 8. 9.0 0. Fittings (Table of Annex C) Openings for fittings 8.. to 8..7 8.. & 8.. Heat Treatment (Table of Annex C) Mechanical tests (Table 6 of Annex C) 9. a)checking of water capacity b) Tensile tests c)hardness Test 0.. to 0.. 0..7 do- Lot Size Frequency Remarks taken from the first five consecutively welded s and one taken from the last fivce consecutively welded s of a production run. From the remaining samples one in fifty shall be selected at random Retest for Radiography shall be as per 7... (b) of IS 899.. Procedure of Repairing of Imperfections disclosed by Radiographic examination shall be submitted by the manufacturer for the approval fo the inspecting authority. This shall include removal of welding by grinding/machining and making a separate batch etc. may be checked by gauging. Records are to be maintained for the first five pieces whenever production starts for each batch or whenever there is a change of tool or its setting. Visual examination only. fitting batch Out of every 00 may be checked by gauging. Records are to be maintained for the first five pieces whenever production starts for each batch or whenever there is a change of tool or its setting. Records to be maintained as per Table of Annex C. If SS sheets are used, heat treatment may not be required. Retesting permitted as per 0..6 of IS 899. Method for determing the water capacity on each shall be declared by the manufacturer. In case the sample fails, the production shall be stopped and the matter investigated for determining the cause of the failure. Page of 8
TEST DETAILS Clause Requirement LEVELS OF CONTROL Test Methods Clause Reference of samples Lot Size Frequency 0.. Hydrostatic Stretch Test (Table 7 of Annex C) 0.. IS 899 Two Consecutive batches. 0.. Burst Test (Table 7 of Annex C) 0.. - 0. Hydrostatic test (Table 8 of Annex C) 0. Remarks The remaining s of this batch shall be checked 00% for this requirement. The production shall be resumed only after the corrective action has been taken and 00% checking for this requirement is done for the next consecutive five batches.the rejected s shall be scrapped by flattening in the presence of the Inspecting Officer. In case of failure in stretch test : (a) Either subject the entire batch to the hydro-static stretch test in accordance with 0.. and reject those that fail in the test or b) Re-heat treat the batch and offer for retest in accordance with 0.. In case of failure in the retest the entire batch shall be rejected. Retest is permitted for the burst test as per clause 0...6 of IS 899. i) In case a is found leaking, the batch to which the belongs shall be tested for hydrostatic test by increasing the retention period of test pressure from 60 sec to 0 sec till no is found leaking in two consecutive batches. ii) Container which have been rejected due to leaks for pin holes blow holes and under cuts in welding or leakage from any part of the except valve pad during hydrostatic test shall be rejected and deshaped in the presence of Inspecting officer. Page 6 of 8
TEST DETAILS Clause Requirement 0. Pneumatic leakage test (Table 8 of Annex C) 0. 0.6. Non Destructive Examination(Table 9 of Annex C) Type test(table 0 of Annex C) a) Bonfire test LEVELS OF CONTROL Test Methods Clause Reference 0.. & 0.. 0.. of samples Lot size Frequency Remarks in three years for each design/size or in case of change in design A representative of each type fitted with all accessories shall be subjected to this test. The shall vent through the pressure relief device and no burst shall occur. After fatique Test burst test shall be carried on the same cylinder. The results shall comply with the requirements of burst test. After the crash test the s shall be subjected to a hydraulic test for a minimum. MPa for atleast 60 sec. The shall not show any leak. This test is meant for special s as per Annex D of IS 899. Records to be maintained for 0.6.. to 0.6..6 b) Fatigue test 0.6.. to 0.6..7 (three s) c) Crash test 0.6... -doto 0.6...8 & 0.6.. d) Strength assessment 0.6.. to 0.6.. Once in a year Every 0. to. s Surface coating and Colour(table of Annex C) Markings (Table of Annex C) Accessories (a) 80 % Stop valve (b) Level indicator (c) Pressure relief valve (d) Remotely controlled service valve with excess flow valve (e) Gas tight housing thickness of coating. shall be checked for the markings as specified in. of this scheme The s shall carry an orientation mark position to install the in correct postion (refer 0.6...6 & 0.6...7). the shall also be marked with the BIS standard mark. shall be fitted with accessories (a) to (h). accessories shall be accompanied with suitable TC. Page 7 of 8
TEST DETAILS (f) Power supply bushing if applicable (g) Non return valve (h) Pressure relief device (fuse to be designed to open at temperature of 0+ o 0 C. Multi function valve IS 00 assembly (Table of Annex C) LEVELS OF CONTROL of 00 Nos or less of similar design batch consignment batch Remarks:. No testing required if valve assembly is carrying BIS standard mark.. Any other valve assembly approved by statutory authority may be used. In such case, suppliers certificate of conformity is required for each batch.. Containers may be supplied without fitting valve assembly as agreed between the manufacturer and the supplier. In such case, the approved type of valve assembly shall be fitted either by the OEM or retrofitter before use. Page 8 of 8