BUREAU OF INDIAN STANDARDS (Western Region …9137 : 1978 Code for acceptance tests for centrifugal, mixed flow and axial pumps — Class C 9283 : 1995 Motors for submersible pumpsets

BUREAU OF INDIAN STANDARDS (Western Region Office, Mumbai)

DRAFT PRODUCT CERTIFICATION MANUAL FOR COMMENTS

Our Ref: DDGW Sectt(PCO/RD) 23 Jan 2014

Sub: Preparation & review of draft manuals for product certification

This has reference to CMD circular CMD-1/31 dtd:11 Nov 2013 on the above subject. In this connection, please find enclosed the draft product certification manuals prepared by WRO as indicated in Annex-I

Kindly examine the draft product certification manuals and forward your comments on the drafts to the ROs/ BO’S indicated against them in Annex-I and a copy of the comments may also be forwarded to at [email protected]

Last date for comments: 3 Feb 2014.

Comments, if any, may please be made in the format as given below:

Sl. Name Clause/ Paragraph / Type of Comments Proposed Change No. of RO / Sub-clause Figure / comment

BO Table (General / Technical / Editorial)

Note: Separate sheets may be attached in case comments are lengthy and cannot be incorporated in the table.

(Rosy Dhawan) Sc ‘E’ & PCO (DDGW Sectt)

BUREAU OF INDIAN STANDARDS

PRODUCT QUALITY MANUAL

OPENWELL SUBMERSIBLE PUMPSET

ISSUE NO. 01 PAGE REV NO. 0

DOC NO. BIS/PQM/OSP

DATE: 20 NOV 2013

PREPARED BY PAGE NO APPROVED BY SANJIV MAINI., Sc D, ABO Page 1 of 36

PRODUCT MANUAL

ON

OPENWELL SUBMERSIBLE

PUMPSETS





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AMENDMENT SHEET

To ensure that each copy of the Product Quality Manual contains a complete record of Amendments, this Amendment page should be updated by controlled copy holders with each set of revised/new pages of the Product Quality Manual. An acknowledgment slip will be sent alongwith revised/new pages of Product Quality Manual for signature and return by all holders of controlled copies





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Amendment No

Date of Issue Section/Page/Clause No

Reason for Change

FOREWORD

This product quality manual contains a description of the product, raw material/components requirements, manufacturing process , in process controls, Certification criteria and Inspection and testing requirement for Openwell submersible Pumpsets as per IS 14220:1994.





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The document control system provides for regular updating of the manual through amendments to various sections. An amendment sheet placed in manual enlists the amendments carried out to the current version of the Manual.

Manual Issue No : 01

Issue Date : 20 Nov 2013





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TABLE OF CONTENTS

Sr. No. Section Contents Page No.





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1 1 Product Description 5 - 6 2 2 Raw Material/components 7 3 3 Manufacturing process and in process Quality controls 8 - 9 4 4 Certification criteria 10 - 12 5 5 Inspection and testing 13 - 14 6 Annexure 1 15 - 17 7 Annexure 2 18 – 22 8 Annexure 3 23 – 26 9 Annexure 4 27 – 29

SECTION NO.1 PRODUCT DESCRIPTION





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1.1 DESCRIPTION OF PRODUCT

Horizontal and vertical Openwell Submersible Pumpset are normally used in open wells for handling clear cold water for application in agriculture, water supply, etc. This works under water and it rest at the bottom of the well. Pump portion is of single stage (horizontal pump) & single or multi stage (Vertical pump).

1.2 LATEST INDIAN STANDARD NO WITH PRODUCT TITLE AND NUMBER OF AMENDEMNTS

IS 14220:1994 Amendment No. 1 to 5 – Openwell Submersible Pumpset

1.3 LIST OF REFERRED INDIAN STANDARDS FOR RAW MATERIAL/COMPONENTS AND TEST METHODS.

LIST OF REFERRED INDIAN STANDARDS

.IS NO. TITLE

210 : 1993 Grey iron castings ( fourth revision )

304 : 1981 High tensile brass ingots and castings ( second revision )

318 : 1981 Leaded tin bronze ingots and castings ( second revision )

613 : 1984 Copper rods and bars for electrical purposes ( second revision )

617 : 1994 Aluminium and aluminium alloy ingots and castings for general engineering purposes ( third revision )

694 : 1990 PVC insulated cables for working voltages up to and including 1 100 V ( third revision )





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1570 (Pt 2/Sec 1) :1979 Schedule for wrought steels :Part 2 Carbon steels (unalloyed steels), Section 1 Wrought products (other than wire) with specified chemical

composition and related properties ( first revision )

1570 (Pt 5) :1985 Schedule for wrought steels : Part 5 Stainless and heatresisting steels ( second revision )

3444 : 1987 Corrosion resistant alloy steel and nickel base castings for general applications ( second revision )

4800 (Part 7) :1970 Enamelled round winding wires : Part 7 Wires with good dielectric properties under humid conditions

5120 : 1977 Technical requirements for rotodynamic special purpose pumps ( first revision )

8783 : 1978 PVC insulated winding wires for submersible motors for 85°C operation

9137 : 1978 Code for acceptance tests for centrifugal, mixed flow and axial pumps — Class C

9283 : 1995 Motors for submersible pumpsets

10572 : 1983 Methods of sampling for pumps

11346 : 1985 Testing set up for agricultural pumps

11723 : 1985 Balance quality of rotating rigid bodies

14582 : 1998 Single phase small a.c. electric motors for centrifugal pumps for agricultural applications

Latest versions of the above standards shall be applicable.

1.4 CHECK LIST FOR SUBMISSION OF APPLICATION FOR GRANT OF LICENCE





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Checklist as enclosed at Annexure 1 may be used for submission of application for grant of licence.





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SECTION NO.2 RAW MATERIAL/COMPONENTS

2.1 LIST OF IMPORTANT RAW MATERIALS INCLUDING THOSE WHICH ARE REQUIRED TO CONFORM TO RELEVANT INDIAN STANDARDS.

As per IS 14220:1994, Clause 6.1 indicates the material of construction . It is mentioned in the clause that some typical material used for construction of Openwell Submersible Pumpset are indicated in Table 1 of IS 14220:1994, which is only for the guidance of the manufacturer and the user. Thus, the conformity to the standard mentioned in Table 1 is not mandatory.





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SECTION NO.3 MANUFACTURING PROCESS AND IN-PROCESS QUALITY CONTROLS

3.1 The manufacturing process of Openwell Submersible Pumpset mainly consists of manufacturing rotor and stator part, which are then assembled to make the Openwell Submersible Pumpset.

Incoming inspection of raw materials consists of visual and dimensional checks. The physical and chemical properties of the raw material are tested in outside laboratory by the manufacturer before use.





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The process of manufacturing of rotor starts with the rotor shaft which is a bought out item. The shaft is taken for machining on lathe machine. After machining the rotor shaft is inspected for length and outside diameter. This is then taken on hydraulic press and the stampings bunch is pressed on the shaft. The rotor is then mounted on lathe machine and machining is done to the required diameter. Keyway is done on the rotor by keyway machine or lathe machine. The rotor outside diameter is then coated with epoxy paint. Thereafter rotor sleeve is grinded on cylindrical grinding machine to obtain surface roughness less than 0.75 Ra. After this the rotor is taken on balancing machine and is dynamically balanced as per Grade 6.3 of IS 11723(Pt.1):1992 .The rotor is thus ready for assembly.

The process of manufacturing of stator starts with the inspection of bought out stator body. The stampings are pressed by hydraulic press inside the stator body.. Thereafter varnishing is done on the inner side by air dry or vacuum varnish machine. Winding coil prepared on winding former is then inserted into the slots of stamping. The cable connection is done to the winding and the winding is tested for insulation test by meggar and high voltage test is also done. The stator is thus ready for assembly.

The rotor is inserted into the stator. Upper and lower housing is fitted and Gun metal bush is inserted at centre of Upper and lower housing. This motor body is then tested for no load test. The dynamically balanced impeller as per Grade 6.3 of IS 11723(Pt.1):1992 is then mounted on rotor shaft with the help of keyway and nut. The volute is fitted with upper housing covering the impeller. Suction inlet and delivery outlet are provided in the volute as per the requirement. Strainer is provided on the suction inlet, drain plug is provided on water inlet and brass plug are provided on air vent. The cable gland is provided with cable for protection. Breather diaphragm is provided on lower housing to control the temperature of water. Screw with washer is provided on the body for earthing purpose. The direction of rotation is marked on the volute by embossing.

The openwell submersible pumpset thus prepared is then taken for testing.

3.2 INFRASTRUCTRE FOR PRODUCTION





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A typical infrastructure required for production is as follows:

1. Lathe machines for machining of casting, rotor, stator, etc. 2. Hydraulic press for fitting of stampings, inserting bush, etc. 3. Induction brazing machine for brazing of stamping. 4. Grinding machine for grinding of sleeve on shaft 5. Baking oven for drying of varnish/paint 6. Cutting machine for cutting of pipe. 7. Drilling machine for drilling of holes, etc. 8. Power saw for cutting. 9. Winding former/ machine for preparation of winding. 10. Bench grinder for grinding of tools. 11. Spray gun for painting 12. Painting booth for painting 13. Material handling equipments





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SECTION NO.4 CERTIFICATION CRITERIA

4.1 IDENTIFICATION OF CRITICAL REQUIREMENT OF THE INDIAN STANDARD

As per CMD note dated 11 Nov 2013, the critical requirements of an Indian Standard shall be determined by a committee comprising the identified officer in the concerned CMD, member secretary of the concerned technical committee and an officer from Central laboratory.

4.2 SCHEME OF TESTING AND INSPECTION

The applicable Scheme of Testing and Inspection is DOC:STI/14220/2, January 2008 and the same is enclosed at Annexure-2.

4.3 MARKING FEE RATES

The marking fee applicable is as follows:

Unit- 1 PUMPSET

Rs 17.3 per unit for the first 200 Units

Rs 10 per unit for the next Rest Units





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Minimum marking fee for large scale units : Rs 39200

Minimum marking fee for small scale units : Rs 32200

4.4 GROUPING GUIDELINES

The grouping guidelines applicable are as per CMD-3 note ref. CMD-III/16:8034/9079/ 14220/9283 dated 04.07.2011 and 10.05.2012 and the same is enclosed at Annexure-3.

4.5 GUIDELINES FOR WRITING SCOPE OF LICENCE

The scope of licence may be written as follows:

“Recommended grant of licence for ‘Openwell Submersible Pumpsets’ as per IS 14220:1994 with Amendment No. 1 to 5 for the varieties mentioned below

Sr. No

Model Delivery Size (mm)

No. of stages

Duty point Motor , Hz, Cat , Type ……… Duty ……

Min Sub. (m)

Head Nom. (m)

Disch. (lps) Nom.

Overall Eff. (%)

Rated Speed (rpm)

Rating (kW)

Max. Current

(A)

Winding Conn.

No. of Phases

Rated Voltage

(V)





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Besides above, in case values of ‘Operating head range’ and ‘Minimum starting Torque (% of full load torque)’ as declared by manufacturer are superior to that given in the specification, the same shall also be mentioned. Also in case of single phase pump the capacitor details, value of capacitor start and run, motor efficiency needs to be mentioned in above format. In addition, if the discharge and/or head range is beyond the graphs depicted in Figure 5 & 6 of IS 14220:1994, pump efficiency factor needs to be declared by the manufacturer and included in above format.

In short, the parameters not declared in the standard and required for testing of pumpsets needs to be mentioned.

4.6 GUIDELINES FOR INCLUSION OF NEW VARIETIES

The inclusion of new varieties may be done as per normal/simplified procedure by testing the samples as per CMD-3 note ref. CMD-III/16:8034/9079/14220/9283 dated 04.07.2011 and 10.05.2012 and the copy of same is enclosed at Annexure-3

4.7 SAMPLE SIZE INCLUDING GUIDELINES FOR DRAWAL OF SEPARATE SAMPLES WHEN SAMPLES ARE REQUIRED TO BE SENT TO DIFFERENT LABS FOR TESTING

Since all the tests as per IS 14220:1994 can be done on a single Openwell Submersible Pumpset, only 1 pumpset shall be sent for testing and no separate raw material are required to be sent.

4.8 MANNER OF SEALING OF SAMPLE





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The sample can be tied with a strong thread and wax sealed with BIS logo seal. Label shall be inserted in the thread before sealing. Alternatively, the sample can be punched with ISI punch on the casing and the code number can be written with marker pen and signed on the pumpset.

4.9 WHETHER REMNANT OF THE SAMPLE ARE RETURNABLE/NON RETURNABLE, TO BE SCRAPPED, USED, TO BE DE-SHAPED BEFORE DISPOSAL IN CASE OF SAFETY ITEMS ANY OTHER PRECAUTION REQUIRED FOR DEALING WITH REMNANTS

The Openwell Submersible Pumpset shall be returned to the licensee/applicant after testing. For this, sample release letter shall be issued both to laboratory and the applicant/.licensee after the test report of the same is received.

4.10 PROCEDURE TO BE FOLLOWED FOR DESTROYING/DE-SHAPING/RECYCLING THE PRODUCT THAT DOES NOT MEET THE QUALITY PARAMETERS DURING REGULAR PRODUCTION

Any rejection during regular production is normally re-cycled by the firm. In case, re-cycling is not possible, the rejection is scrapped. Also since the product is not under mandatory certification, the products not conforming to BIS requirements are often sold as non ISI product.





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SECTION 5 INSPECTION AND TESTING

5.1 PACKING MATERIAL REQUIREMENTS TO BE AVAILABLE IN FACTORY FOR PACKING/DESPATCH OF SAMPLES

For sealing of samples, sealing wax, strong thread, blank yellow labels, candle, match box, permanent marker is required. The samples can then be packed in cardboard/wooden boxes.

5.2 LIST OF REQUIRED TEST EQUIPMENTS/FACILITIES WITH REQUIREMENT AND FREQUENCY OF CALIBRATION

As per note a) of typical framework of Product Manual, the list of test equipment is to be prepared /provided by CL.

5.3 STATUS OF TEST FACILITIES IN BIS LAB AND OSLs WITH TESTING CHARGES AND APPROXIMATE TIME REQUIRED FOR TESTING BY BIS LABS/OSLs.





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The testing facility for Openwell Submersible Pumpset is not available in any of the BIS labs. The details of testing facilities available in OSL along with testing charges is enclosed at Annexure-5.

The testing time required for one pumpset is 2 days maximum.Thus, the testing time required shall be not more than 7 days depending upon the work load in the laboratory and the number of samples sent for testing.

5.3 WHETHER GRANT OF LICENCE WILL BE BASED ON - FACTORY TESTING BASIS OR - INDEPENDENT TESTING BASIS OR - MIXED

Since complete testing facilities are available in the laboratories, grant of licence will be based on independent testing basis.

5.4 DETAILS OF TESTS TO BE CARRIED OUT IN THE FACTORY IN CASE OF - APPLICANT SAMPLE/VERIFICATION SAMPLE - SURVEILLANCE/MARKET SAMPLES - RAW MATERIAL SAMPLES TO BE GOT TESTED IF ANY

All the tests as required as per IS 14220:1994 can be carried out in the factory in case of applicant sample/verification sample/surveillance sample. No separate raw material sample needs to be tested.





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ANNEXURE 1.

CHECK-LIST FOR APPLICATION TO BE SUBMITTED BY APPLICANT TO BIS





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WHILE APPLYING FOR BIS LICENCE UNDER PRODUCT CERTIFICATION SCHEME OF BIS

The following check-list is required to be submitted with all the applications for grant of BIS licence under the Product Certification Scheme of BIS. Please tick (√) in the relevant box.

Whether applied under: Simplified Procedure Normal Procedure

Note: Refer BIS website or details of “Simplified Procedure” and “Normal Procedure” for grant of licence.

No. Check-point Requirement Observations Page

No. General Is the application form completely filled?

1. Name &

Address

Is the name and address of applicant (manufacturing unit

applying for licence) same in the application as given in the

2. Status of

Applicant

(Manufacturing

Unit)

a. Has it been indicated whether the applicant is a large scale or

small scale unit?

b. In case the applicant is a small scale unit, does the applicant

hold valid Registration Certificate from the Local / State

authority or from a Chartered Accountant, and is the certificate

c. Has it been indicated whether the applicant is a Public Sector

or a Private Sector company?

3. IS No. &

Varieties

a. Has applicant recorded the applicable Indian Standard with

correct title of the Standard?

b. Where applicable, has applicant mentioned designation,

grade, type, variety, size, etc., of the product for which the BIS

5. History a. Where applicable, has the applicant provided information

regarding earlier BIS licence(s) held by them and / or

b. Where applicable, has the applicant provided information

regarding BIS licences currently held by them?

6. Signature a. Is the application signed by the CEO of the applicant?

b. In case the application is signed by a person other than the

CEO, is the application signed by the authorized signatory of

the applicant and his authorization is attached by the





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7. Machinery a. Does applicant possess requisite manufacturing infrastructure

to manufacture the product as per the Indian Standard?

b. Is installed capacity of production indicated in the application?

c. Does applicant have all machineries installed as per

manufacturing process at the applicant’s manufacturing

d. If answer to ‘c’ above is no, does the applicant outsource any

of its manufacturing processes and possesses valid

agreement(s) with other manufacturing units for the

e. If answer to ‘d’ above is yes, does the applicant has any

control over such outsourced activity? Are these outsourced

process will ensure testing the quality of final product for all

8. Test Equipment

&

Calibration

a. Does applicant possesses requisite test facilities in-house as

per the relevant Indian Standard at its factory address?

b. Are valid calibration certificates for relevant test equipment

attached are complete and valid at least 3 months after the

c. If reply to ‘a’ above is no, does applicant have arrangement

with a BIS recognized outside lab for testing of the

requirements for which it does not possess test facilities in-

house? Is the consent letter as attached by applicant in this

regard in order?

Note: Relaxation in in-house test facilities may be allowed on

9. QC personnel Does the applicant employ qualified & experienced Quality

Control (QC) personnel on permanent basis and possess

documentary evidence to establish the same? Are the copies of

10. Raw Materials

and

Components

Where ever requirements for raw materials/ components used in

the manufacturing of the product are specified in the standard, do

test reports/suppliers’ test certificates, as submitted by the





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11. Plant Layout Does copy of the plant (applicant manufacturing premises) layout

clearly indicates locations of manufacturing machinery,

12. Test Report(s) a. Is the attached test report of in-house or from independent

laboratory cover all requirements of the Indian Standard and is

b. In case the application is filed under “simplified Procedure” is

the test report(s), in original, as submitted a) from BIS or its

recognized laboratories? b) the test report is not older than

one month from the date of submission of application, c)

13. Undertaking In case application is under simplified procedure, an undertaking

shall be obtained from the applicant on his letter-head that the

licence if granted against his application shall be put under Stop

Marking by BIS if the verification sample(s) (any sample including

the long duration test samples) drawn during visit of the BIS

officer prior to grant of licence fail to conform to the requirements

of relevant Indian Standards. The licensee shall take necessary

corrective actions and inform the same to BIS along with fresh

samples (of rating/size/variety which facilitates verification of

corrective actions on the reported failures) manufactured after

taking the corrective actions. The resumption of marking in such





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ANNEXURE 2 STI





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ANNEXURE 3 GROUPING/GUIDELINES





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ANNEXURE 4

List of BIS Laboratories

Date :- 20/11/2013

Record not Found !

Lab Quantity Lab Type Testing Facility Remarks

Record not found !

IS No. Testing Charges Remarks

Testing Facility:: C=Complete Test facility / P=Partial Test Facility/ N=No Test Facility

List of Outside Recognized Laboratories

IS Number :- IS 14220 - OPENWELL SUBMERSIBLE PUMPSETS

Sl No.

Name of the Recognized Laboratory Lab Code Testing Charges Remarks





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1 Electronics and Quality Development Centre

B 177/178, GIDC Electronics Estate

Sector-25

Gandhinagar-382044

Gujarat

Contact : Mr. L.S. Sharma, Director

Tel : 079-23287119/20/22

Fax : 079-23287121

7118234 Upto 3.7kW-Rs.3,750/-, Above 3.7kW to 7.5kW- Rs.4,000/-, Above 7.5kW to 11 kW-Rs.4,750/-, Above 11kW to 15 kW-Rs.5,000/-, Above 18kW to 20 kW-Rs.5,250/-, Above 20 kW to 45 kW-Rs.7,250/-,

2 MSME Development Institute

386, Patel Road

Ramnagar

Coimbatore-641009

Tamilnadu

Contact : M. Palanivel, Deputy Director

Tel : 0422-2233956,

Fax : 0422-2230426

6105534 Pump only:- Rs.3,700/- upto 3.7kW; Rs.3,800/- above 3.7kW & upto 7.5kW; Rs.4,000/- above 7.5kW & upto 11kW; Rs.4,700/- above 11kW & upto 15kW. Pumpset:- Rs.6,500/- upto 3.7kW; Rs.7,000/- above 3.7kW & upto 7.5kW; Rs.7,700/- above 7.5kW & upto 11kW; Rs.9,200/- above 11kW & upto 15kW.

3 NSIC Technical Services Centre

80 Ft. Road, Near Bhavnagar Road

Crossing,

Aji Industrial Area

Rajkot-360003

Gujarat

Contact : Shri N.K. Subramani, Deputy

General Manager

Tel : 0281-2387613,2387396

Fax : 0281-2387729

7104734 Rs.4320/- Upto 3.7kW; Rs.5040/- above 3.7kW to 7.5kW; Rs.5760/- above 7.5kW to 11kW; Rs.6120/- above 11kW to 15kW; Rs.6480/- above 15kW to 20kW; Rs.7200/- above 20 kW to 25kW; Rs.7920/- above 25kW to 30kW; Rs.8424/- above 30kW to 35kW; Rs.9000/- above 35kW to 40kW; Rs.9504/- above 40kW to 45kW; Rs.10800/- above 45kW to 50kW; Rs.12600/- above 50kW to 60kW; Rs.14400/-





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above 60kW to 70kW; Rs.17280/- above 70kW to 100kW

4 Scientific & Industrial Testing & Research Centre

83 & 84, Avarampalayam Road,

K.R. Puram P.O.

Coimbatore-641006

Tamilnadu

Contact : Sh. K. Gunabal, Joint Director

Tel : 0422-2562612,2560473

Fax : 0422-2562612

6104904 Rs.7500/- upto 3.7 kW, Rs.8100/- above 3.7 kW & upto 7.5 kW, Rs.9200/- above 7.5 kW & upto 11.0 kW, Rs.11500/- above 11.0 kW & upto 15.0 kW, Rs.15700/- above 15.0 kW & upto 20.0 kW, Rs.18200/- above 20.0 kW & upto 25.0 kW, Rs.20700/- abvoe 25.0 kW & upto 30.0 kW, Rs.23100/- above 30.0 kW & upto 35.0 kW, Rs.26200/- abvoe 35.0 kW & upto 40.0 kW, Rs.27300/- abvoe 40.0 kW & upto 45.0 kW, Rs.29500/- above 45.0 kW & upto 50.0 Kw

5 Electrical Research & Development Association

P.B. No. 760, ERDA Road,

Makarpura Industrial Estate

Vadodara-390010

Gujarat

Contact : Dr. M.K. Shah, JD&Quality

Manager -Mob:09978940911

Tel : 0265-2642942,964,377

Fax : 0265-2648382

7101125 upto 5.5kW: Rs.5505/-, 5.5kW to 11kW :Rs.6745/-, 11kW to 22 kW:Rs.7850/-, 22kW to 45kW :Rs.10820/- [25% discount for

-





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Documents

BUREAU OF INDIAN STANDARDS (Western Region …9137 : 1978 Code for acceptance tests for centrifugal, mixed flow and axial pumps — Class C 9283 : 1995 Motors for submersible pumpsets