Doc:STI/9798/5 August 2003

SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF LOW PRESSURE REGULATORS FOR USE WITH LIQUIFIED PETROLEUM GAS (LPG) MIXTURES ACCORDING TO IS 9798:1995 (Incorporating Amendment No.1, 2 & 3)

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. TEST RECORDS: All records of tests, inspection and calibration shall be kept in suitable forms approved by the Bureau. All testing apparatus/measuring instruments shall be periodically checked and calibrated and records of such checks/calibration shall be maintained. Copies of any records and other connected papers that may be required by the Bureau shall be made available at any time on request. 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]. In addition, effort should be made to gradually introduce a quality Management system in accordance with IS/ISO 9000 series as appropriate to the activities of the organization. STANDARD MARK: The Standard Mark, as given in Column (1) of the first Schedule of the licence, shall be marked on each low pressure regulators for use with LPG, provided always that the regulator to which this Mark is thus applied conforms to every requirement of the specification. MARKING: In addition each regulator shall be provided with the following information on the regulator: a) b) c) d) e) f) g) The manufacturers name or trade mark; The month and year of manufacture; Rated capacity in m3/h of gas designed for; Serial number of regulator, if required; Name of gas, designed for; Any other markings as agreed to between the purchaser and the manufacturer; and License Number (CM/L.)

2.

2.1

2.2

3.

3.1

4.

4.1

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NOTE: The location and size of CM/L number to be marked on regulators is given in Annex D. 5.0 CONTROL UNIT: For the purpose of this scheme, the control unit shall consist of a lot of regulators manufactured in a day under similar process of production. LEVELS OF CONTROL: The tests, as indicated in Table 1 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. Each control unit of finished regulators shall be offered for inspection to BIS before dispatch. The sampling and criteria of conformity for the lot inspection given in Annex A of this scheme shall be followed; Regulators failing to meet the requirements of the specification shall not be marked with the BIS Standard Mark. A certificate shall be issued by the Bureau in respect of regulators approved for marking with BIS Standard Mark as per proforma given at Annex B. test certificate proforma is applicable for commercial butane propane mixture (LPG) and for other gases proforma may be modified accordingly. The material shall conform to the requirements specified in Clause 4.1 and 4.2 of IS 9798:1995. A test certificate shall be supplied by the supplier for each consignment of material. Material of the diaphragm shall conform to the requirements as specified in clause 4.3 of IS 9798:1995. A test certificate shall be supplied for each consignment of material. Material of the valve pad shall conform to the requirements as specified in clause 4.4 of IS 9798:1995. The frequency of different tests shall be as indicated in Table1. The Bureau shall have the discretion of making an independent check test, if necessary, of diaphragm and valve pad material. At the time of approval of prototypes, the regulator shall be checked, for conformity to all the requirements of IS 9798:1995. Whenever there is a change in material or design of the regulator, it shall be retested and shall conform to all the requirements of the specification. A drawing giving outline dimensions and materials of construction shall be provided along with the prototypes.

6.0

6.1

6.1.1

6.2

6.2.1

6.2.2

6.2.3

6.3

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7.0

In respect of all other clauses of the specification and at all stages of manufacturer, the factory shall maintain appropriate control and checks to ensure that their product conforms to the various requirements of the specification. 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 licence 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 of 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 quality produced, marked and exported by him and the trade value thereof at the end of each operative year of the license. Table 1.

8.0

9.0

10.0

10.1

11.0

11.1

12.0

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IS 9798: 1995 LOW PRESSURE REGULATORS FOR USE WITH LIQUIFIED PETROLEUM GAS (LPG) MIXTURES TABLE 1 LEVELS OF CONTROL (Para 6.0 of the Scheme of Testing and Inspection)
TEST DETAILS Clause Requirements
LEVELS OF CONTROL

Test Method Reference

No. of Samples

Lot Size

Frequency

Remarks

Clause 4. 4.1 & 4.2 Material. Regulator body Material

4.1 & 4.2 IS 9798

One

One consignment

Each consignmen t

In case material is received with test certificate indicating chemical composition no further testing is required. -do-

4.1 4.1.1

Components material. Brass parts

4.1 4.1.1

-doIS 9798& IS 2305

-do-do-

-do-do-

-do-do-

4.3 4.3.1

Diaphraga Material Porosity and smoothness surface 4.3.1 IS 9798 0.25% subject to a minimum of 8 All the diaphrag m of the same quality in a consignnment -do-doEach lot See note 1

4.3.2 4.3.3

Clamping test Accelerated ageing test.

4.3.3 3 or 4

-doIS 3400 (Pt.4)

-doOne

-do-do-

See Note 1 Test may be carried out on representative slab/button. See Note 1. See Note 1

4.3.4

Pull out and burst.

Annex B

of IS 9798

One sample per 1000

regulators

or part thereof. 4.3.6 4.4 Flexible test Valve pad Material 4.3.6 -do-do-

All the regulator s assemble d in one day. -do-

Daily

-do-

-do-

Doc:STI/9798/5 August 2003

IS 9798: 1995 LOW PRESSURE REGULATORS FOR USE WITH LIQUIFIED PETROLEUM GAS (LPG) MIXTURES TABLE 1 LEVELS OF CONTROL (Para 6.0 of the Scheme of Testing and Inspection)
TEST DETAILS Clause Requirements
LEVELS OF CONTROL

Test Method Reference IS 9798

No. of Samples

Lot Size

Frequency

Remarks

Clause 4.4.1 Porosity and surface smoothness test. 4.4.1

0.25 per cent subject to a minimum of 8 One

All the valve pad of the same quality in a consignment

Each
consignment

See Note 1

4.4.3

Accelerated ageing test.

3 or 4

IS 3400 (Pt.4)

-do-

-do-

Test may be carried out on representative slab/button Pl. See Note 1

Type Tests 6.3 Hydrostatic Test 6.3 IS 9798 3 One unit control Each control unit -do-doEach week -do-dovalve Each lot See Note 1 (See Note 2)

5.6 5.7.2 8.10.1 8.10.2 8.10.3 4.3.5

Outlet connection. Body Cycle Test Low Temperature Test. High Temperature Test. Immersion diaphragm. test for

5.6 5.7.2

-do-do-

-do-do4 -do-do1 1000 pads 1000 pads

-do-doWeeks

8.10 & 8.10.1 -do-do-doAnnex C -do-do-do-

production -do-do-

4.4.2

Immersion test for valve pad. Immersion test for valve pad fitting in its housing.

-do-

-do-

valve

-do-

-do-

4.4.2

Annex D

-do-

1000 valve pads fittings in its housing

-do-

-do-

Doc:STI/9798/5 August 2003

IS 9798: 1995 LOW PRESSURE REGULATORS FOR USE WITH LIQUIFIED PETROLEUM GAS (LPG) MIXTURES TABLE 1 LEVELS OF CONTROL (Para 6.0 of the Scheme of Testing and Inspection)
TEST DETAILS Clause Requirements
LEVELS OF CONTROL

Test Method Reference

No. of Samples

Lot Size

Frequency

Remarks

Clause Routine Tests 4.2.1 Finish a) Corrosion resistance test.

IS 9844

One

One control unit One control unit Each regulat or 0.25% subject to a min. of 8 Each regulat or -do-

Once in a week.

b) Adhesion test for painted or powder coated surface. 5.2 Construction & Workmanship (inclusive of knob operation) Inter Changeability/leak proof test for inlet connection.

Annex G IS 9798

One

Each control unit.

5.2

IS 9798

5.5

Annexure C of this scheme

All the regulators assembled in one day.

6.2 & 6.4 8.9

Pneumatic Test.

6.2& 6.4

IS 9798

Chatter and performance test.

8.9.1 & 8.9.2 -do-

NOTE 1: If any of the sample fail twice the number of samples shall be tested from the same consignment. In case of further failures, the entire consignment (lot) shall be rejected. NOTE 2: Cycle test shall be carried out for 20,000 cycles with air at specified pressure. However, in the beginning at the time of design approval for each type of regulator, this test shall be for 100,000 cycles as per clause 8.10.1 of IS 9798:95.

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ANNEX A (Cl. 6.1 of STI) Subject: Sampling Plan for Lot Inspection for Certification of LPG regulators as per IS 9798:1995. All the regulators of the same size manufactured from the same material under similar conditions of production shall be grouped together to constitute a lot. Sample for lot inspection shall be selected depending on the number of regulators in a lot as given below: Lot Size Upto 500 501 1001 3001 10001 Sample Size 20 32 50 80 125

1000 3000 10000 and above

Criteria for Acceptance of a lot Each of the regulator selected in the sample shall be subjected to the following tests: a) Construction and workmanship (cl. 5.2) (inclusive of knob operations) Inter-changeability (Cl. 5.3) Outlet connection (Cl. 5.6) Pneumatic test (Cl. 6.2, 6.4) Chatter (Cl. 8.9.2) Performance test (Cl. 8.9.1)

b) c) d) e) f)

3 regulators from the selected samples of each lot shall be tested for hydrostatic test (Cl. 6.3). A regulator failing to meet any of the requirements of above tests shall be termed as defective. The lot shall be accepted if no defective is found in the sample; otherwise not. If the lot is rejected at the first instance, then no further testing is done. However, if a corrective action has been taken and thereafter a lot has been re-offered, then the same sampling criteria should be applied as indicated above.

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ANNEX B (Cl. 6.1.1 of STI) Name and address of the manufacturer TEST CERTIFICATE FOR LPG PRESSURE REGULATORS Certificate No. : Batch No.(s) : Purchaser : Date: Order No. & Date:

Description : Low Pressure LPG regulator (Max. working Pressure 16.87 kgf/cm2) 500 /h outlet for 6.4/7mm Rubber Tubing to be used on SC valves with 22.0/25.6 mm outlet diameter. This is to certify that the following regulators are inspected and tested by BIS Officer(s) on ________ at M/s _________ in accordance with scheme of testing and inspection attached with BIS License No._________ meet the requirement of IS 9798:1995 & drawing No.___________ approved by Chief Controller of Explosives vide letter No._________ dated _________. Raw Material Specification:

Suppliers Name: Chemical Composition (%)

Test Cert. No. & Date:

-----------------------------------------------------------------------------------------------------------A1 Mg Cr Pb Fe Zn Impurities -----------------------------------------------------------------------------------------------------------Specified -----------------------------------------------------------------------------------------------------------As per T.C. -----------------------------------------------------------------------------------------------------------Remarks ------------------------------------------------------------------------------------------------------------

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Regulators bearing Sr. Nos. from Manufactured from

to

covered by batch nos. similar raw material are checked/tested for the following: Specified Parameter No. of Pieces Inspected/Accepted/Rejected

1.

Construction & Workmanship (including knob operation) (Cl.5.2) Interchangeability (Cl.5.3)/ leakproof test for inlet connection (Cl. 5.5) Soundness test (Cl.6) Pneumatic test (Cl.6.4) (from outlet) Pneumatic test (Cl.6.2) (from outlet) Hydrostatic test (Cl.6.3)

IS 9798

2.

IS 9798

3. a)

b)

c)

4. 5. 6.

Outlet Connection (Cl. 5.6) Chatter (Cl.8.2.8.9.2) Performance test (Cl.8.9.1)

Test Pr. 17 kgf/cm2 (1.666 M Pa) Test Pr. 150 gf/cm2 (14.70 kN/M2 Test Pr. 25.4 kgf/cm2 (2.49 Mpa) IS 9798 IS 9798 Outlet Pr. Observed Pr (mm) WC) Min. Max min.225 mm WC

a.

0.5 kgf/cm2 Inlet Pressure 100% flow rate (500 l/h) 17.0 kgf/cm2 inlet pressure 10% flow rate (50 l/h) 17.0 kgf/cm2 Inlet pressure lock up

b.

max. 400 mm WC

c.

max. 450 mm WC QUANTITY PASSED:

QUANTITY OFFERED: SR. NO. OF REGULATORS REJECTED:

Method of disposal of rejected regulators: Deshaped/Dismantled Q.C. Incharge NAME Designation Date BIS Inspecting Officer NAME Designation Date

Doc:STI/9798/5 August 2003

ANNEX C (Table 1 of STI)

Interchangeability Procedure for Leak-proof test for inlet connection of LPG pressure regulator as per clause 5.5 IS 9798 and Table 1 of this Scheme. The manufacturer shall provide to the inspector two self closing spring loaded LPG valves manufactured as per customers requirements, one with all tolerances on the minimum side and another with all tolerances on the maximum side for this check For checking proper fitment and locking up with self closing spring loaded LPG valves, regulators to be coupled with the two pieces of valves provided as above and hydrostatic/pneumatic tests carried out with the valve in open position at the pressure of 25.4 kgf/cm2 /17.0 kgf/cm2 to check that there is no leakage from the regulator inlet portion as also from the valve outlet and the regulator inlet joint (the regulator orifice to be closed to lock up position by applying pneumatic pressure greater than 450 mm of water column through outlet of regulator).