BUREAU OF INDIAN STANDARDS (Southern Regional Office) · 10 Packer Head/Duplex Head and Flanges Cast Iron Gr FG 200 of IS 210 Note: As per Cl 7.0 of STI for IS 12225, Test Certificates

BUREAU OF INDIAN STANDARDS (Southern Regional Office) Our Ref: 60/CM 1 6 Dec 2013 Subject: Preparation & Review of Product Manuals for Product Certification This has reference to CMD-I’s circular CMD-1/31 dated 11 Nov 2013 on the above subject. In this connection, the draft Product Manual in respect of IS 12225 allotted to SRO has been prepared. The same is attached herewith for hosting on the BIS Intranet for inviting suggestions and comments for a period of 15 days. The comments may be sent to SRO/ CBTO. (H.L. Upendar) DDGS Encl: a/a HITSD BIS HQ E. DEVENDAR Scientist G & Deputy Director General (South) Bureau of Indian Standards Southern Regional Office IV Cross Road, C.I.T. Campus Tharamani, Chennai - 600 113 Email: [email protected] Phone: 044 - 2254 2365 Fax: 044 - 2254 1087

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PRODUCT MANUAL Centrifugal Jet Pump – IS 12225

PRODUCT MANUAL

on

CENTRIFUGAL JET PUMP As per

IS 12225

BUREAU OF INDIAN STANDARDS NEW DELHI

Verified by: Approved by:

DOC. : CJP1 DATE: 25 NOV 2013

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REVN. No. 0 DATE: 25 NOV 2013


AMENDMENT HISTORY

S.No. Date of Amendment

Amendment No.

Doc. No. Amendment Details

Need for Amendment

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DOC.: CJP1 DATE: 25 NOV 2013 REVN. No. 0 DATE: 25 NOV 2013


FOREWORD

This product manual is established to facilitate the Applicants on the Product- Centrifugal Jet Pumps as per IS:12225 to understand the technical aspects involved in product Certification by Bureau of Indian Standards. Details on the Product Standard, the Standards of Raw materials, as applicable, manufacturing process and in-process quality controls, Certification criteria, Inspection & Testing etc. are outlined in this manual.

All Standards are subject to revision and the users are encouraged to identify the most recent

editions of the standards and its corresponding amendments issued. At the time of establishing this manual, the specification IS 12225 corresponded to year 1997 edition with Two amendments issued to its standard.

The Applicants are requested to study this manual and understand the requirements

thoroughly before applying for BIS Certification as per IS 12225.

BIS New Delhi

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Table of Contents

S.No. Section No. Document Details 1 1 Product Description 2 2 Raw Materials/Components 3 3 Manufacturing Process/

In-Process Quality controls 4 4 Certification Criteria 5 5 Inspection & Testing

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Section 1 –Product Description

1.1. Description of Product: Centrifugal jet Pumps described in the standard IS 12225 are those types of pumps which are capable of lifting ground water from depths beyond 8m suction lift. This capability becomes in built in Centrifugal Jet Pumps by virtue of a Jet Unit which is essential part of Centrifugal Jet Pumps. The standard IS 12225 specifies the requirements of single and multistage Centrifugal Jet Pumps used for pumping water from wells beyond the suction capacity of any horizontal or vertical end suction centrifugal pumps. In small sizes, this type of pumping unit is widely used for domestic water supply.

1.2 Latest IS No. /Product Title/No. of Amendments:

Centrifugal Jet Pump as per IS 12225: 1997 with Two Amendments. 1.3. List of referred Indian Standards for Raw Materials /Components/Test Methods: 1.3.1 Raw materials /Components: A few typical materials are indicated below for guidance of the manufacturer and the user. The materials listed below are only typical and indicative of minimum requirements of the materials properties. The use of materials having better properties is not prejudiced by the details below, provided materials for components in bearing contact with each other do not entail galling, corrosion, magnetic induction, etc.

S. No. Components Material of construction 1 Nozzle Brass Grade HTB1 of IS 304 or

Bronze LTB2 of IS 318 or suitable Thermoplastics or Stainless Steel Gr 04 Cr13, 12Cr13, 20Cr13 of IS 6603 or Cast Iron Gr FG 200 of IS 210, PTFE, ABS Polymers.

2 Venturi Brass Grade HTB1 of IS 304 or Bronze LTB2 of IS 318 or suitable Thermoplastics or Nylon 6 or Nylon 66, Glass filled Nylon or Stainless Steel Gr 04 Cr13, 12Cr13, 20Cr13 of IS 6603 or Cast Iron Gr FG 200 of IS 210, PTFE, ABS Polymers.

3 Foot Valve Brass Grade HTB1 of IS 304 or Bronze LTB2 of IS 318 or suitable Thermoplastics or Nylon 6 or Nylon 66, Glass filled Nylon or Stainless Steel Gr 04 Cr13, 12Cr13, 20Cr13 of IS 6603 or Cast Iron Gr FG 200 of IS 210, PTFE, ABS Polymers.



PRODUCT MANUAL

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Centrifugal Jet Pump – IS 12225 4 Strainer of Foot Valve Brass Grade HTB1 of IS 304 or Cast Iron

Gr FG 200 of IS 210 or HDPE or LDPE or Glass filled Nylon.

5 Jet Pump (Assembly) Body Cast Iron Gr FG 200 of IS 210 or Bronze LTB2 of IS 318 or Brass Grade HTB1 of IS 304 or suitable Thermoplastics such as PPO, PC Nylon 6 or Nylon 66,or Glass filled Nylon or PTFE

6 Impeller Cast Iron Gr FG 200 of IS 210 or Bronze LTB2 of IS 318 or Brass Grade HTB1 of IS 304 or suitable Thermoplastics such as PPO, PC Nylon 6 or Nylon 66,or Glass filled Nylon or PTFE

7 Casing Cast Iron Gr FG 200 of IS 210 or corrosive resistance alloy steel and nickel base casting.

8 Pressure Regulating Valve:

a) Body Cast Iron Gr FG 200 of IS 210 or Bronze LTB2 of IS 318 or Brass Grade HTB1 of IS 304 or suitable Thermoplastics such as PPO, PC Nylon 6 or Nylon 66,or Glass filled Nylon or PTFE or Stainless Steel Gr 04 Cr13, 12Cr13, 20Cr13 of IS 6603 or Cast Iron Gr FG 200 of IS 210 or PTFE,ABS,PET.UHMWPE

b)Diaphragm Neoprene Rubber or Nitrile Rubber c) Valve Seat Bronze LTB2 of IS 318 or suitable

Thermoplastics such as PPO, PC Nylon 6 or Nylon 66,or Glass filled Nylon or PTFE, ABS, PET.

9 Slip Coupling (Optional) for Twin Type

a)Body Cast Iron Gr FG 200 of IS 210 b) Sealing Ring Neoprene Rubber or Nitrile Rubber 10 Packer Head/Duplex Head

and Flanges Cast Iron Gr FG 200 of IS 210

Note: As per Cl 7.0 of STI for IS 12225, Test Certificates showing conformity to the relevant specifications given under IS 12225 for each consignment of Raw Materials/Components shall be obtained from Suppliers, as far as possible. Verified by: Approved by:


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1.4 Check list for submission of an application for Grant of Licence: Check list for submission of an application for Grant of Licence is enclosed in Annexure under the file name: “Check list” which may pl. be referred to by the Applicants before submitting their applications to BIS for Grant of Licence. Contd……….



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Section 2 Raw Materials/Components 2.1 List of important Raw Materials/Components including those which are required to conform to the relevant Indian Standards: Section 1.3.1 of this manual dealing with Raw Materials/Components may be referred to for the above details.

Section 3 Manufacturing Process and In-process Quality Controls

3.1 A typical Manufacturing Process and In process Quality Controls for Centrifugal Jet Pumps is described in the attached file in the name “Mfg. Process & Controls” in the form of Process Flow Chart which is self explanatory. In- process check points are indicated at their respective stages to ensure product conformity to IS 12225 and firm’s declared performance characteristics.

Contd…….

Verified by:

DOC.: CJP1 DATE: 25 NOV 2013

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Approved by:

REVN. No. 0 DATE: 25 NOV 2013


3.2 Infrastructure* for Production of CENTRIFUGAL JET PUMP- IS: 12225

S.NO. NAME OF THE MACHINERY

1 CUTTING MACHINES

2 LATHES

3 DRILLING MACHINES

4 GRINDING MACHINES (CYLINDRICAL/ SURFACE GRINDERS)

5 BEARING PRESSES

6 HYDRAULIC PRESSES

7 HAND GRINDER

8 COMPRESSOR (FOR PAINTING)

9 COIL WINDING MACHINES WITH FORMERS & COUNTERS

(Manual or Motorised)

10 PAINTING GUN & PAINTING BOOTH

11 FITTING & ASSEMBLY TOOLS, TABLES (VISES,ANVILS,,ETC)

12 DYNAMIC BALANCING MACHINE (FOR ROTOR & IMPELLER BALANCING )

13 HAND DRILLINGMACHINES 14 VARNISH IMPREGNATORS 15 WEIGHING M/cs 16 WATER SUPPLY , EB POWER & DG SET POWER BACK UP

*Note: The above list is only a typical and indicative of general infrastructure (General Purpose Machines) required for mfg. of various components/sub assemblies and assembly of Centrifugal Jet Pump. Depending upon the size of operation, volume of production, use of modern technology such as CNC machines and more number of machines may be adopted for production. Further, the use of such machinery at the mfg. premises may also depend on the extent of outsourcing of machining of components or purchase of readily available components from the firm’s selected and approved vendors with suitable Quality Assurance systems to ensure conformity to the requirements.



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Section: 4 CERTIFICATION CRITERIA

4.1 Identification of critical requirements of the Indian standard IS 12225: 4.1.1. Dynamic Balancing of Die Cast Rotors

4.1.2. Prime Mover/Motor Test 4.1.2.1 For Electric Motor Driven Pumps: (Cl. 5.2.1)

a) Earthing Requirement, Reduced Voltage Running up Test, No Load Test b) Insulation Resistance Test

c) High Voltage Test d) Insulation Resistance Test (after HV Test) e) Locked Rotor Test e) Temp Rise Test set at Maximum current in DLWL range at Rated Voltage and at Reduced voltage

4.1.2.2. For Engine Driven Pumps- (Cl. 5.2.2)

The Engines either Diesel or Petrol run Engines, shall conform to IS 10001/IS 11170 for Diesel Engines or IS 7347 for Petrol engines. For critical components of the Engine, Refer Cl. 3.1 and Table for Prime Mover Engine Drive of STI for IS 12225

4.1.3. Pump Tests:

a) Hydraulic Pressure Test for Pump casing and Jet unit (Cl. 9.3) b) Pump Performance Test (Cl. 8.3, Cl.9.1 , Cl.9.2 & Cl.10 and Tables 1, 1A and 2 ) 4.2 Reference of Indian Standards/Documents for Product Test Method:

1. IS 12225- Cl. 8.1 read with Annex-B, Cl. 8.2,Cl. 8.3, Cl. 9.1, Cl. 9.2 and Cl.10 read with Tables 1, 1A and 2. 2. IS 11346:2002- Cl. 11 and 12.

3. Scheme of Testing & Inspection for IS 12225 –Doc. STI/12225/2 Feb 1999

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4.2- Scheme of Testing & Inspection (STI)for IS 12225 Doc. No. STI/12225/2 Feb 1999

Pl. Refer to file “ STI-IS 12225 ” for viewing the above STI

4.3- Marking Fee Rates are in INR MARKING FEE for IS 12225:1997

Description Value

Unit ONE PUMP

L S Marking Fee 34000

S S Marking Fee 29000

Slab 1 Rate 8.7

Slab 1 Qty All

Slab 2 Rate 0

Slab 2 Qty 0

Slab 3 Rate 0

Enforcement Date 20120806

Remarks

Legends: L S –Large Scale organizations S S – Small Scale Organizations. 4.4- Grouping Guidelines: BIS certification of Centrifugal Jet pumps as per IS 12225 is done on individual pump model basis. There are no grouping guidelines for grant of licence or for inclusion of new

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varieties. Verified by: Approved by:



4.5: Guidelines for writing Scope of Licence: The product varieties of Centrifugal Jet pumps are described in the scope as follows: Product Description: Centrifugal Jet Pump IS No: IS: 12225 Type of Jet Arrangement: Twin Type or Duplex Type or Packer Type to be indicated for each model of the pump. In addition, the performance characteristics as “Pump Duty Chart” of Centrifugal Jet pumps as declared by the manufacturer for each variety of pump will be attached to the scope of licence. The Format for declaring the performance Characteristics by the manufacturer is attached in the file “Perf Characteris-12225” for Electric Motor Run Centrifugal Jet Pumps. However, for Engine - Run Pumps, the details of Prime Mover such as Engine Rating and Engine Speed are to be indicated in place of Electric Motor details. 4.6 Guidelines for Inclusion of new varieties in licence: The new varieties which are to be included in licence are to be independently tested (I/T)fully for conformity as per IS 12225 either through Normal Procedure or through Simplified Procedure. The pump varieties are to be independently tested, type-wise, individually for considering inclusion. Details of Normal Procedure and Simplified Procedure for BIS Certification are available in BIS website www.bis.org.in under Product Certification. 4.7- Sample Size including guidelines for drawal of separate samples when samples are required to be sent to different labs for testing: One number of fully assembled Centrifugal Jet Pump and one number of Jet unit for each variety of pump offered for certification, shall be drawn for independent testing. As raw materials are only recommendatory as per IS 12225, there are no conformity tests required for raw materials/components. 4.8- Manner of Sealing of samples: The samples drawn for independent testing shall be labeled for each sample with the following details: Model name/ Motor Rating or Engine Rating/ S.No:/Date of Mfg./IS 12225. The label with the above details shall be counter signed by the Inspecting Officer and be attached with the sample and sealed with BIS Seal for forwarding to I/T Labs. Similarly, one jet unit also shall be drawn, labeled with details linking the pump model name/S.No for which it is to be used for testing and be sealed as above.

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4.9 Details of actions to be taken on Remnants of samples after testing is completed. Since the samples of pumps do not get damaged or destroyed or de shaped during the course of independent testing, the remnants of the sample can be taken back from the lab after completion of I/T for further use. There are NO special precautions required to be taken for dealing with remnants of samples.

4.10- Procedure to be followed for destroying/de shaping/re cycling the product that does not meet the Quality Parameters: For the products that do not meet the minimum requirements as per IS 12225 and its declared parameters, the firm shall investigate the causes of failure through Root Cause Analysis and take necessary Corrections and Corrective Actions on the product/systems to ensure conformity. After incorporating the corrections, the product is required to be re-tested for conformity. If the product does not meet the requirements even after the corrections, then the product does not qualify for Standard Mark (ISI Mark). The Scheme of Testing and Inspection shall also be referred to and be strictly followed by the BIS licensees during operation of the licence.

The BIS licensees are encouraged to establish Quality Management Systems (QMS) as per IS/ISO 9001:2008. For details visit BIS Website www.bis.org.in under BIS Management Systems Certification for Quality Management Systems.

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Section 5- INSPECTION AND TESTING 5.1- Packing Material Requirement (to be available at factory at all times) for Packing & Dispatch of samples: Corrugated carton boxes of adequate strength and size depending on the type of pump to be dispatched shall be available at all the time to facilitate packing of pump & jet unit. In case the pump is too heavy, the same may have to be packed in wooden crates to ensure safe transportation to I/T labs. 5.2 List of required Test Equipment/facilities is to be provided by CL as per Note (a) of the Annex-2 of the note CMD-1/31 dtd 11 Nov 2013. Requirement & Frequency of Calibration: All Testing apparatus/test equipment shall be periodically checked and calibrated and records of such checks/calibrations shall be maintained. The calibrations may preferably be done from NABL Accredited laboratories if available or otherwise through laboratories having Master References/Standards having traceability to National Standards. The periodicity of calibrations may be decided upon the usage :

Instrument Name Voltmeters, Ammeters, Wattmeters, Flow meter, HV Tester, Thermometer, Volumetric Tank Frequency Meter, IR Tester, Resistance meter Pressure Gauges, vacuum Gauges,Spring Balances, Stop watch, Prme Mover (Motors )- for Engine Run Pumps

5.3 Status of Test Facilities in BIS labs/Outside Labs (OSLs) with Testing Charges and approximate time required for testing by BIS Labs/OSLs: The maximum time required for complete testing of one pump is six hours by BIS Labs/OSLs. The status of testing labs by BIS Labs/OSLs and their Testing Charges can be obtained from BIS

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Website “www.bis.org.in” under Product Certification. The actual time taken by the labs may be more depending upon the number of samples in queue for testing. However, the details of outside laboratories and Testing Charges by these OSLs are given below for ready reference. It is to be noted that the Testing Charges are subject to review and changes. Verified by: Approved by:



LIST OF OUTSIDE RECOGNIZED LABORATORIES & TESTING CHARGES IS 12225- CENTRIFUGAL JET PUMP

Sl No.

Name of the Recognized Laboratory Lab CODE Testing Charges

Remarks IS Number :- IS 12225 CENTRIFUGAL JET PUMP

1 MSME Development Institute 386, Patel Road Ramnagar Coimbatore-641009 Tamilnadu Contact : M. Palanivel, Deputy Director Tel : 0422-2233956, Fax : 0422-2230426

6105534 Single phase Jet Centrifugal Pump: Rs. 4,800/- upto 1.5 kW Three Phase Jet Centrifugal Pump: Rs.4,800/- upto 3.7kW; Rs.5,500/- above 3.7kW & upto 7.5kW; Rs.6,300/- above 7.5kW & upto 11kW; Rs.7,300/- above 11kW & upto 15kW

2 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.5400/- for single phase upto 1.5 kW

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3 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 Rs.6735/- [25% discount for BIS]



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5.4 Basis for Grant Of BIS Licence: The grant of BIS certification will be based only on independent testing of samples of the product for full conformity as per IS 12225. 5.5 Details of Tests to be carried out in the factory in case of

a) Applicant Samples/Verification samples:

All the tests on the product as given under Section 4.1.2 & 4.1.3 of this manual excluding Temperature Rise Tests to the extent of verifying the Testing Competency of the Quality Assurance personnel and to verify the working condition of different test equipment. If time permits, Temperature rise Tests can also be carried out.

b) Surveillance samples/Market samples:

Surveillance Tests: For Normal periodic Surveillance Tests, all the tests under Section 4.1.2 & 4.1.3 of this manual excluding Temperature Rise Tests. In case of Market Samples, complete testing is required to be done only at BIS Labs/OSLs.

c) Resumption of Marking Samples: All Tests under Section 4.1.2 & 4.1.3 of this manual excluding Temperature Rise Tests. In case, the periodic sample had failed in Temperature rise Test, then Temperature Rise Tests have also to be carried out.

d) Raw Material Samples:

As per IS 12225, the material of construction of various components are only for guidance and hence, NO I/T is required for Raw Materials.

However, as per Cl 7.0 of STI for IS 12225, test certificates showing conformity to the relevant specifications given under IS 12225 for each consignment of raw Materials/Components shall be obtained from Suppliers, as far as possible.

END OF DOCUMENT Verified by: Approved by:


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