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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: nlbo@bis.org.in.
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
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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.
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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