Doc: STI/3196 (Part1)/13, October 2016 · doc: sti/3196 (part1)/13, october 2016 3 scheme of testing and inspection for certification of welded low carbon steel cylinders exceeding

Doc: STI/3196 (Part1)/13, October 2016

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भारतीय मानक ब्यरूो (कें द्रीय महुर विभाग 3)

हमारा सदंभभ : सी एम डी 3/16 : 3196 (Part 1) 18 नवबंर 2016

विषय : आई एस 3196 (Part 1) : 2013 (सशंोधन सखं्या 1 सहित) के लिए, पनुरीक्षित एस टी आई Doc: STI/3196 (Part1)/13, October 2016 का अनपुािन आई एस 3196 (Part 1): 2013 (सशंोधन सखं्या 1 सहित) के लिए पनुरीक्षित एस टी आई Doc: STI/3196 (Part1)/13, October 2016 अनपुािन िेत ुसिंग्न िै। पनुरीक्षित एस टी आई में clause 7.0 के अतंर्गत “Batch” के पररभाषा को सशंोधन सखं्या 1, अर्स्त 2015 के अनसुार सशंोधधत ककए र्ए िै। सिम प्राधधकारी ने अनपुािन िेत ुएस टी आई को अनमुोहित कर हिया िै। सभी िेत्रीय और शाखा कायागियों से अनरुोध िै की उपरोक्त हिशाननिेश का अनपुािन तत्काि प्रभाव से सनुनश्चित करें।

(अममत कुमार)

िजै्ञाननक सी (सी एम डी-3)

प्रमखु (सी एम डी-3)

सभी िेत्रीय /शाखा कायागिय/एम.ई.डी प्रनतलिपप : आई टी एस पवभार् , बी आई एस इंट्रानेट पर डािने िेत।ु


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BUREAU OF INDIAN STANDARDS

(Central Marks Department-3)

Our Ref: CMD-III/16:3196 (Part 1) 18 November 2016

Subject: Implementation of revised STI, Doc: STI/3196 (Part1)/13, October 2016 for IS 3196

(part 1): 2013 (with amendment No. 1)

Doc: STI/3196 (Part1)/13, October 2016 for IS 3196 (part 1): 2013 (with amendment No. 1) is

enclosed for implementation. In this revised STI definition of “Batch” under clause 7.0 is

modified in line with Amendment No. 1 August 2015.

The Competent Authority has approved the STI for implementation.

All ROs/BOs are requested to ensure the implementation of the above guidelines with immediate

effect.

(Amit Kumar)

Sc. C (CMD-3)

Head (CMD-3)

Circulated to: All ROs/BOs/MED

Copy to: ITS for hosting on Intranet


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SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF WELDED LOW

CARBON STEEL CYLINDERS EXCEEDING 5 LITRE WATERCAPACITY FOR LOW

PRESSURE LIQUEFIABLE GASES PART 1 CYLINDERS FOR LIQUEFIED PETROLEUM

GASES (LPG) ACCORDING TO IS 3196(Part.1) : 2013

(SIXTH REVISION)

(Including Amendment No. 1)

1.0 LABORATORY/TESTING STATION – Laboratory/testing stations commensurate with production

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.

1.1 All testing instruments/equipments shall be periodically checked and calibrated. Records of such

checks/calibration shall be maintained.

1.1.1 Tensile testing machines shall be calibrated once in a year.

1.1.2 Various pressure gauges used shall be calibrated at least once in a month.

1.1.3 The pyrometer used for heat treatment furnace shall be calibrated once in every six months.

1.1.4 Testing instruments/equipments shall be carried out periodically from NABL accredited

calibration 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. All records of such calibrations to be kept.

2.0 TEST RECORDS - All records of tests and inspection shall be kept in suitable forms approved by BIS

2.1 Copies of any records or connected papers that may be required by BIS shall be made

available at any time on request.

2.2 For all stages of manufacture, the factory shall maintain appropriate controls and checks to

ensure that their product conforms to the various requirements of the Standard

3.0 QUALITY CONTROL The manufacturer shall maintain a Quality Control Department and shall

enforce proper inspection at all stages of manufacturing as per the schedules at Annexure A and Table 1, to

ensure that each cylinder 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 of the product during production as envisaged in this Scheme. [See IS

397(Part 1), IS397 (Part 2), IS 397(Part 3) and IS 397(Part 4)]. In addition, effort should be made to

gradually to introduce Quality Management system in accordance with IS/ISO 9001: 2008. All units

supplying cylinders to PSUs will obtain Quality Management System certification in accordance with

IS/ISO 9001: 2008 from BIS


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4.0 ACCESS TO INSPECTION: As per Clause 12 of IS 3196 (Part 1):2013

4.1 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.

5.0 STANDARD MARK – The Standard Mark, as given in Column (1) of the First

Schedule of the licence, shall be stamped on a non-detachable and non-pressure part of the

cylinder, provided always that each cylinder, so marked conforms to every requirements

of the specification.

5.1 OTHER MARKING: Each cylinder shall be marked with the following at the bung:

a) Serial number of the cylinder;

b) Manufacturer’s identification symbol;

c) Tare weight;

d) Year of manufacture;

6.2 Each cylinder shall also be marked with in accordance with Clause 20.1 and 20.2 of IS 3196

(Part1):2013 and any other marking as required in the approved drawing.

(Note: - the tare weight shall include the weight of the valve fitted to the cylinder).

7.0 CONTROL UNIT: For the purpose of this scheme, Batch and Inspection Lots shall be as

under:

Batch – A batch shall consist of finished cylinders not exceeding 3000 cylinders made

consecutively by the same manufacturer using the same manufacturing technique, to the same

design, size and material specifications on the same type of automatic welding machines and

subject to the same heat treatment conditions. A batch may contain material from more than one

cast. (Amendment No.1 to IS 3196 Part 1: 2013)

- Inspection Lots - for acceptance purposes the batch shall be divided into inspection lots not

exceeding 1000 cylinders. For selection of sample cylinders for either burst or mechanical tests,

each lot is divided into sub-lots of 250 cylinders (see Fig.1 of IS 3196 Part 1: 2013) The samples

taken for ‘mechanical or burst test’ shall be alternated between the mechanical and burst tests

(Clause 3.7.1 of IS 3196 Part 1: 2013)

7.1 The identity of each control unit/batch shall be maintained.

7.2 The tests as indicated in Annexure ‘A’ and Table 1 and at the levels of control specified

therein shall be carried out on the whole production of the factory covered by this Scheme and

appropriate records and charts maintained in accordance with paragraph 2 above.


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7.3 A certificate as per Annexure ‘B’ shall be issued by the BIS Inspecting Officer in respect of

every batch/inspection lots of cylinders marked with BIS Standard Mark

7.4 The period of manufacture/inspection/test shall be taken from the date of release of steel

to the date of final inspection/testing.

7.5 All pressing and cylindrical shells shall be examined for surface defects before any seam

is welded. No pressing or shell having defects beyond the acceptable limits shall be used.

7.6 Should any pressing or shell be of thickness less than the minimum specified thickness, all

output from the relevant batch of material shall be examined for minimum thickness, and any

pressing or shell found to be less than the specified minimum thickness shall be rejected and de-

shaped by pressing.

7.7 Before being fitted with valves all cylinders shall be thoroughly cleaned and dried internally.

7.8 Preparation for Despatch: Requirements as per Clause 23 to be complied with. The outside

surface shall be shot blasted and shall be given a protective coating as given in Cl.22.2 of

IS:3196(Part1):2006 before dispatch.

8.0 MATERIAL – As per Clause 4 of IS 3196 (Part) 1: 2013

9.0 DESIGN & FABRICATION - In respect of design, fabrication/ manufacture, the cylinder

shall conform to clause 6 to 10 of IS 3196(Part I): 2013

9.1 Welding consumables used shall be as per Clause 7.8 of IS 3196 (Part 1): 2013. To ensure

this, chemical analysis shall be arranged by the firm on the samples of drillings of weld wire and

flux combination. The tests may not be necessary if test certificate is received along with the

consignment (flux and wire). Nevertheless, samples shall be analysed once in every quarter as a

confirmatory check.

10.0 HEAT TREATMENT

10.1 After completion of all inspections satisfactory, the cylinders shall be punched with Sl.

Nos. before putting them for heat treatment.

10.2 All cylinders shall efficiently and uniformly normalized or stress relieved according to

Clause 11.1 & 11.2 of IS 3196 (Part 1): 2013. Localized heat treatment shall not be permitted

[(Refer to Clause 11.3 of IS 3196(part1):2013]

(NOTE: Care shall be taken to ensure the consistency of heat treatment cycle, the rise and fall of

temperature curve shall be within the declared temperature range. In case the temperature falls

below the lower limit, the furnace cycle shall be stopped and restarted only after attaining the


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requisite temperature. The records of heat treatment cycle and interruptions of cycle shall be

maintained.)

11.0 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 the

specification.

12.0 REJECTION: A separate record shall be maintained giving information relating to the

rejection of products which do not conform to the Indian Standard and the method of their

disposal. Such products shall in no case be stored together with those conforming to the Indian

Standard.

13.0 SAMPLES: The licensee shall supply free of charge, the sample or samples required in

accordance with Bureau of Indian Standards (Certification ) Regulation, from his factory or

godown. BIS shall pay for the samples taken by it from the open market.

14.0 REPLACEMENT: Whenever a complaint is received soon after the product with Standard

Mark have been purchased and used, and if there is adequate evidence that the product has not

been misused, defective product shall be 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 conformity of the product to the Indian Standard shall be with BIS.

The firm shall have own complaint investigation system as per IS/ISO 10002

In the event of any damages caused by the product 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 the licensee and

BIS shall not in any way be responsible in such cases

15.0 STOP MARKING: The marking of the product shall be stopped under intimation to BIS, if

at any time, there is some difficulty in maintaining the conformity of the product to the Standard,

or the testing equipment goes out of order. The marking may be resumed as soon as the defects

are removed under intimation to BIS. The marking of the product shall be stopped immediately if

directed by BIS for any reason. The marking may then be resumed only after permission by BIS.

The information regarding resumption of marking shall also be sent to BIS.

13.0 PRODUCTION DATA: The licensee shall send to BIS as per the enclosed Proforma-1

authenticated by a Chartered Accountant, a statement of quantity produced, marked and exported

by them and the trade value thereof at the end of each operative year of the license.


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.ANNEXURE ‘A’

STAGE INSPECTION FOR MANUFACTURE OF LPG CYLINDERS

1. MATERIAL: As per Table 1; levels of control

2. Manufacture / Assembly of Components

Pressings/Halves/

Cylinder shell

Valve Pad/Bung Joggle Joint Foot Ring Valve Protection

(Cl.10.3 IS

3196P1)

(Cl. 7.3 IS 3196

P1)

(Cl.10.2 IS 3196

P1)

(Cl. 9.3 IS 3196

P1)

a) Check Blanking

(circle making),

drawing/pressings

and trimmed

halves for surface

defects

(each piece -

visual)

a) Check

forgings for

surface defects

(each - visual)

a) check for

dimensions (each

piece - may be

checked by

gauging) and

surface defects.

(each piece -

visual)

a) check for

dimensions(hourly

5 pieces) and

surface

defects(each piece

- visual)

a) check for

dimensions

(hourly 5 pieces)

and surface defects

(each piece-

visual).

b) Check of

height to

maintain water

capacity

(first five pieces at

the start of

production and

two pieces every

hour. May be

checked by

gauging )

b)Each piece to be

checked for Finish

as per Annex B of

IS 3196(Part

1):2013

Dimensions to be

checked for 5

pieces

hourly

b) Check

for Marking

(hourly 5 pieces)

b) Check

for Marking

(hourly 5 pieces)

c) Degreasing

(each piece – in

case of any oil

trace, the piece to

degreased again)

c)welding: each

piece

c)welding: each

piece

c) welding; each

piece

3. Assembly & Manufacture

a) Inspect welding defects of the body, bung, foot ring and valve protection

b) Heat treatment (Ref Table 1; Levels of Control)

c) Select cylinders for acceptance test, bursting test and water capacity

d) Check for quality of grit blasting, protective metal coating and painting.

e) Check tare weight (with valve fitted to the cylinder)


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ANNEXURE ‘B’

Purchaser: _______________________ ____________________ Certificate No. : _______________________

Order No. : ___________________________________________ Date: ___________________

Batch No.: ___________________ Inspection Lot No.: ___________________________________________

Cylinder Description : _______litres water capacity. Two/three piece LPG Cylinder, working pressure _______

Test pressure _______ MPa . Manufacturer’s identification mark __________

This is to certify that the cylinders manufactured, inspected and tested as mentioned below during the period from

___________ to ________________at M/s ______________________________ meet the requirements of

specification IS 3196(Pt.1):2013, Drawing No. ___________ The cylinders have been fitted with ISI marked valves

Method of Manufacture Acceptance Test

1. Welding process : Sl. No. of Cylinders:

2 Method of Support: : Joggling

3 Heat treatment : Normalized/Stress Relieved at _____ ºC for___ Mints.

INSPECTION Min Max

The cylinders have been inspected and Yield stress

Tested in accordance with scheme of (MPa)

Testing and inspection attached with Tensile Strength

BIS licence no. CM/L-____________ (MPa)

Percentage elongation

Material for Cylinder: IS 6240/IS 15914

TESTS

Hydrostatic Test : Satisfactory

(Test Pressure___________Mpa )

Pneumatic leakage test : Satisfactory

(Test Pressure ____________ Mpa ) Bend Test

Face : Satisfactory

Bursting Test : Root : Satisfactory

Sl. No. of Cylinders Macro Examination

Burst Pressure ( Mpa): Min.- Max.- Body : Satisfactory

Cylinder bursted without fragmentation Neck : Satisfactory

Nominal Hoop Stress( Mpa) Min. Thickness: ___ mm

____________________________________________________________________________________________

Cylinder Nos. _______________ to____________ of ______________ batch are covered under Acceptance test

cylinder no. ___________ and burst test cylinder no. ________ of ___ batch. These have been heat treated in the

same manner and manufactured from steel of similar chemical composition and mechanical properties which had

been produced by same steel manufacturer

_____________________________________________________________________________________________

QUANTITY INSPECTED : Cylinders Serial No. from ____________ to _____________inclusive

Serial No. of REJECTED CYLINDERS ___________________________________

TOTAL No. of Cylinders Passed __________________________________________

(Signature) INSPECTING OFFICER

Name & Designation of the Bureau of Indian Standards

Officer representing the Company


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PROFORMA - 1

PROFORMA FOR OBTAINING PRODUCTION DETAILS

Period covered

Name of Licensee

CM/L No.

Name of Articles (s)

Grade/Type/Size/Variety/Class/Rating IS No.

1.1 Brand/Trade/Name(s) of BIS Certification Marked Products

2.0 Total production of the articles(s) Licensed for certification marking

2.1 Total production of the article(s) Conforming to Indian Standard

3.0 Production covered with BIS Certification Mark and its

Value : a) Quantity

b) Value (Rs.)

3.1 Brand Name used on production covered under BIS Certification Mark

3.2 Calculation of marking fee on unit-rate basis; Marking Fee per unit

a) Unit

b) Quantity covered with BIS Certification Mark

c) Marking fee rounded off in whole rupees as obtained by applying unit rates given in (a)

on quantity given in (b)

NOTE: In case a clause is not applicable, suitable remarks may be given against it

4.0 Quantity not covered with BIS Certification Mark. If any,

reasons for such non-coverage

4.1 Brand Name under with non-certified goods were sold

5.0 Quantity Exported with BIS Standard Mark and its value

5.1 Brand Name under which BIS Certified goods are exported

6.0 Authentication by Chartered Accountant


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Welded Low Carbon Steel Cylinders Exceeding 5 Liter Water Capacity for Low Pressure

Liquefiable Gases Part 1 Cylinders for Liquefied Petroleum Gases (LPG) according to IS 3196 (Part

1): 2013

Table 1; Levels of Control

Clau

se

Requirement Test Method Levels of Control Remarks

Claus

e

Reference Samples Lot

size

Frequen

cy

5;6 Design and

Drawing

5;

6

IS 3196

Part1:2013

-Drawings shall be

approved by statutory

authority

- Agreed finished

thickness shall not be

lower than that

calculated as per Clause

6 of IS 3196 Part1:2013

4 Material

Material for

cylinder shell

4.1;

4.1.1;

4.1.2

IS 3196

Part1:2013;

IS 6240;

IS 15914

Each consignment of

material to be supported

with manufacturer’s test

certificate heat/cast

wise.

Valve pad/bung 4.2 IS 3196

Part1:2013;

IS 1875;

IS 2062

-do-

Foot ring, stout

metal cap shroud

, stay plate

4.3 IS 3196

Part1:2013;

IS 1079;

IS 2062;

IS 6240

-do-

Protective ring 9.3.3 IS 3196

Part1:2013

-do-

Valves 9.1 IS 3196

Part1:2013;

IS 8737

Each consignment of material to be supported with

manufacturer’s test certificate

8;

12

Manufacture/

construction

IS 3196

Part1:2013

Pressings/

Halves/

Cylinder shell

8.4;

8.5;

12;

IS 3196

Part1:2013;

IS 9639

i) Each to be examined before closing in operation for

surface defects (external and internal). Only those

conforming to be used for further processing. Rejected

ones to be deshaped in such a way that it cannot be used

at any stage.

ii) 2% or more to be examined randomly for minimum

thickness before any seam is welded. If any piece is less

than the minimum specified thickness, the whole output

from the relevant batch of material shall be examined


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for minimum thickness and any piece which is less than

the specified minimum thickness shall be deshaped in

such a way that it cannot be used at any stage.

For above, batch of material is defined to mean

pressings/halves/cylindrical shells manufactured in a

continuous run.

iii) Circularity, profile regularity, straightness and

verticality shall be checked according to 8.5.1, 8.5.3,

8.5.4 and 8.5.5 of IS 3196 Part1:1993. Rejected ones to

be deshaped in such a way that it cannot be used at any

stage.

iv) The above examination shall be done after

degreasing.

Bung Hole

Making

8.5 IS 3196

Part1:2013

Each

piece

-In case of any non-conformance, the piece

to be rejected and to be deshaped in such a

way that it cannot be used at any stage.

-Each piece may be checked by gauging.

Welding of

cylinder and

attachments/fit--

tings

7;

10.1;

10.2;

10.3

IS 3196

Part1:2013

Each Cylinder Joggle joint shall be

according to 7.3 of IS

3196 Part1:2013

11 Heat Treatment 11.1;

11.2;

11.3

IS 3196

Part1:2013

Each cylinder i)Heat treatment shall

be done according to

11.1/11.2 of IS 3196

Part1:2013.

ii)Record of Heat

treatment cycle shall be

kept

iii)Localized heat

treatment not permitted

13 Radiographic

examination

(when required)

13.1,

13.2,

13.3;

10

IS 3196

Part1:2013

IS 3196

Part3:2012

As per 13.1; 13.2.1; 13.2.2 of

IS 3196 Part1:2013

In case of failure, to

follow procedure as per

10.4 of IS 3196

Part1:2013

14 Checking for

water capacity

14 IS 3196

Part1:2013

One

cylinder

Each

Inspect

—ion

lot

Every

100

cylinde-

-rs or

part

there of

In case of failure,

remaining cylinders to

be 100 % checked. The

rejected cylinder to be

scrapped by flattening/

deshaping. The

production to be

stopped and reasons of

failure to be

ascertained. Normal

Production shall be

resumed after corrective

actions taken and 100%

checking done for this

requirement for next

four inspection lots.


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15 Hydrostatic test 15

And

7

IS 3196

Part1:2013;

IS 3196

Part3:2012

Each

cylinder

The test may be carried

out using suitable

adapter at the bung. For

rejected cylinders, to


Clause 7.2 & 7.3 of

IS 3196 Part3:2012

16 Valve fixing and

Pneumatic

leakage test

16;

8

IS 3196

Part:2013;

IS 3196

Part3:2012

Each

cylinder



Clause 8.4 of IS 3196

Part3:2012

17

Fatigue

Testing/cycle

testing

17;

9.3

IS 3196

Part1:2013;

IS 3196

Part3:2012

One

sample

consis-

-ting of

three

cylinde

—rs as

per

17.1.1

of IS

3196

Part 1:

2013

One

inspect

--ion

lot

Type

Test

Type Test and required

to be done for initial

approval or whenever

there is a change in

design, raw material of

cylinder or asked by

BIS for specific reason.



9.3 of IS 3196

P3:2012. The test

sample shall be one

sample consisting of

three cylinder as per

17.1.1 of IS 3196

(Part 3): 2013. These

cylinders shall be from

one inspection lot

pertaining to batch not

exceeding 3000

cylinders.

17.2

Burst Test Under

Hydraulic

Pressure

17.2

&

9.1

IS 3196

Part1:2013

&

IS 3196

Part3:2012

Clause 3.7.1 and

Fig.1

Of

IS 3196 Part1:

2013

Each

batch

not

exceed-

-ing

3000

cylinder

In case of failure in

burst test, to follow

procedure as per clause

9.2 of IS 3196

Part3:2012

18 Acceptance Test

(Mechanical

Test)

18

&

5

IS 3196

Part1:2013

&

IS 3196

Part3:2012

In case of failure in

acceptance test, to


clause 5.7 of IS 3196

Part3:2012

19 Additional Test

(Impact and

Drop Tests)

Annex C of

IS 3196 Part1:2013

i)For cylinders manufactured from steel as per IS 15914

ii) Type Test for initial approval or whenever there is a

change in design, raw material of cylinder or asked by

BIS for specific reason

iii) samples shall be according to Annex C of

IS 3196 Part1:2013 from one inspection lot

10.1 Test for Handle

or other suitable

10.1 IS 3196

Part1:2013

One cylinder Each

inspect--

In case of failure,

remaining cylinders to


13

arrangement ion lot be 100 % checked. The

rejected cylinder(s) to

be scrapped by

deshaping.

21 Colour

Identification

21 IS 3196

Part1:2013

Each cylinder

23 Preparation for

Despatch

23 IS 3196

Part1:2013

Internal cleaning

and drying

16.1

&

23.1

IS 3196

Part1:2013

Each cylinder

Grit blasting 23.2 IS 3196

Part1:2013

Each cylinder

Protective

Coating

23.2 IS 3196

Part1:2013

Each cylinder

Coating

thickness

23.2 IS 3196

Part1:2013

One

cylinder

Each

inspect

-

-ion lot

Every 50

cylinde--

rs

20.2 Tare weight 20.2 IS 3196

Part1:2013

Each cylinder (with valve fitted to the cylinder)

Documents

Doc: STI/3196 (Part1)/13, October 2016 · doc: sti/3196 (part1)/13, october 2016 3 scheme of testing and inspection for certification of welded low carbon steel cylinders exceeding