draft product certification manual for comments - … · rope brake drum (in case of rope brake...

DRAFT PRODUCT CERTIFICATION MANUAL FOR COMMENTS Our Ref.: NRO/CHBO(MCM) 05 Dec 2013 Please find enclosed the following draft certification manual: Product manual on Performance Requirements for constant Speed Compression Ignition (Diesel) Engines for General Purposes (up to 19 kW) as per IS 10001: 1981 Kindly examine the draft product certification manual and forward your comments on the draft manuals. Last date for comments: 20 Dec 2013. Comments, if any, may please be made in the format as given below and mailed to CHBO (MCM) at the following email id: [email protected]. 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 incase comments are lengthy and cannot be incorporated in the table.

Product manual on Performance Requirements for constant Speed Compression Ignition (Diesel) Engines for General Purposes (up to 19 kW) as per IS 10001: 1981 Prepared by: MDCH-2 Approved by:

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Product Manual On

Product manual on Performance Requirements for constant Speed Compression Ignition (Diesel) Engines for General Purposes (up to 19 kW) as per IS 10001: 1981


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Amendment Sheet


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Foreword

This product manual contains the description, manufacturing, and testing of Performance Requirements for constant Speed Compression Ignition (Diesel) Engines for General Purposes (up to 19 kW) as per IS 10001: 1981 Guidelines for Grant of BIS licence for an applicant is also described in this manual. Information about laboratories where the product can be got tested for the purpose of Grant of Licence etc. are described in the manual for the easiness of a new applicants as well as existing licensees.


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Table of Contents

Sr. No. Contents Page Nos.

1. Section I 5-9

2. Section II 10-10

3. Section III 11-14

4. Section IV 15-33

5. Section V 34-36


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Section I: Product Description Description of Product

This specification was evolved to help the user to quote the power, specific fuel consumption, lubricating oil consumption, etc, for ordering purposes. This Standard lays down the performance requirements of constant speed compression Ignition (Diesel) engines for general purposes (up to 19kW)

This Standard is not applicable to:

a) Pressure – charged engines,

b) Engines for ship propulsion or marine auxiliaries,

c) Engines for aircraft propulsion or aircraft auxiliaries, and

d) Engines for rail or road traction.

Latest Indian Standard Number with Product title and number of Amendments

IS 10001: 1981

Product manual on Performance Requirements for Constant Speed Compression Ignition (Diesel) Engines for General Purposes (up to 19 kW) as per IS 10001: 1981 No. of Amendments: 06


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List of Referred Indian Standards for Raw Materials/ Components and Test Methods

a) IS 10000(Part-1): 1980, Methods of tests for internal combustion engines: Part 1 Glossary of terms relating to test methods shall apply.

b) IS 10000(Part-2): 1980, Methods of tests for internal combustion engines: Part 2 Standard reference conditions.

c) IS 10000(Part-4): 1980, Methods of tests for internal combustion engines: Part 4 declarations of power, efficiency, fuel consumption and lubricating oil consumption.

d) IS 10000(Pt-V): 1980 Methods of tests for internal combustion engines: Part V Preparation for tests and measurements for wear,

e) IS 10000(Pt-VI): 1980, Methods of test for internal combustion engines: Part 6 recording of test results.

f) IS 10000(Pt-VII): 1980 Methods of tests for internal combustion engines: Part VII Governing tests for constant speed engines and selection of engines for use with electrical generators.

g) IS 10000(Pt-VIII): 1980 Methods of tests for internal combustion engines: Part VIII Performance tests,.

h) IS 10000(Pt-IX): 1980 Methods of tests for internal combustion engines Part IX Endurance tests,

i) IS 10000(Part-XI): 1980, Methods of tests for internal combustion engines Part XI Information required with enquiry or order and information supplied by the manufacturer with the engine.

j) IS 10000(XII): 1980, Methods of tests for internal combustion engines Part XII test certificates.


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k) IS 10000(Part-XIII): 1980 Methods of test for internal combustion engines: Part XIII recommendation on nature of tests required for functional changes in critical components.

l) IS 8178-7: 1996 Reciprocating internal combustion engines – Exhaust emission measurement – Part 7 : Engine family determination.

Check –list for submission of an application for grant of licenc a) Checklist for application to be submitted by applicants to BIS while applying for BIS


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licence


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b) List of documents to be attached with application.


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Section II: Raw Materials/Components


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Following are the major critical components/Drawings used for the manufacturing of constant Speed Compression Ignition (Diesel) Engines for General Purposes (up to 19kW) as per IS 10001: 1981

1. Design details and drawings of critical components and fly wheel(s)

2. Cylinder Head 3. Crank Case 4. Cylinder Block 5. Cylinder Liner 6. Inlet and exhaust valves 7. Valves guides 8. Tappets 9. Piston and Rings

10. Governor weights and Fly wheel(s) 11. Connecting Rod 12. Crank Shaft 13. Main Bearings

14. Big end bearing and small end bearing bush for connecting rod.

15. Connecting rod bolts and nuts. 16. Camshaft, cams and timing gears 17. Valve springs and governor springs (wherever applicable) 18. Fuel injection equipment, such as fuel injection pump, high

pressure pipe, injector/nozzle and nozzle holder 19. Lubricating oil pump 20. Sealing gaskets (only for cylinder head gasket) 21. Gudgeon pin 22. Rocker arm, and

Section III: Manufacturing Process and In-Process Quality Controls


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Description of Manufacturing process(es) A typical flow chart indicating manufacturing process is depicted below:

critical components

Testing

Assembly Product test

Labeling, schedule of maintenance, lub. Oil changes

and overhauls etc.

Packing with accessories and spare parts if any

Store

Infrastructure for Production


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A Unit may need the following machineries in manufacturing the constant Speed Compression Ignition (Diesel) Engines for General Purposes (up to 19kW) as per IS 10001: 1981

1. Tool Room and Assembly line(s) 2. Go & No Go plug gauges 3. Go & No Go snap gauges 4. Ring gauges 5. Thread (plug and ring) gauges 6. Guage control and calibration facilities 7. Inside and out side micro-meters 8. Vernier Callipers 9. Height guage(s) 10. V. Block & magnetic stand 11. Feeler guage(s) 12. Depth guage(s) 13. Dial gauges 14. Slip gauge set 15. Comparator 16. Dial bore gauges and master rings 17. Surface plates 18. Arrangements for checking dimensions such as ring grooves in piston

(special slips or any other) 19. Hardness tester 20. Spring tester 21. Crank detector (recommendatory only) 22. Nozzle tester for pressure and spray pattern 23. Lub-oil pump tester 24. Fly-wheel balancing equipment(s) 25. Cam setting and rocker arm setting details checking equipment

26. Hydraulic pressure testing equipment for liner, cylinder head, cylinder block etc.


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27. Connecting rod alignment checking ring for twist, bend and bow 28. Crank shaft alignment and pin parallelism checking ring 29. Balances (preferably self indicating type) 30. High pressure fuel pipe flushing equipment 31. Torque wrench(s) for tightening of balance weights, studs and nuts,

etc. 32. Compression pressure tester 33. Gear marking apparatus 34. Valve timing apparatus 35. Arrangement for checking bumping, clearance 36. Alignment of bearing housing for crank shaft 37. Arrangement for checking clearance of rings and ring gaps 38. Any other controls/equipment 39. Standard Room with complete information about reference gauges,

master gauges, profile projector, tool room details, if any, metrological and temperature controls etc.

Testing for Rating


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a) Test bed(s) with suitable dynamometer(s)and loading arrangement(*) b) Pressure gauges c) Barometer d) Hygrometer/humidity indicator(or dry and wet bulb thermometers

with humidity chart) e) Tachometer/stroboscope (instantaneous type) f) Fuel measuring apparatus g) Stop watch h) Thermometers/pyrometer(s) temperature gauges i) Hydrometer(s) for sp, gravity of fuel and lub oil j) Exhaust back pressure gauge/manometer k) Suitable water circulation arrangements for water cooling engine, for

rope brake drum (in case of rope brake dynamometer) for hydraulic dynamometer etc, for maintaining consistency in working temperatures

l) Equipment for governing test m) Equipment for determination of mechanical efficiency

(recommendatory) n) Apparatus for determination of calorific value of fuel. o) Apparatus for determination of lubricating oil consumption.

* Note 1 – Electronic/Hydraulic dynamometer for engines above 1000 rev/min rating and rope brake dynamometer for engines up to and including 1000 rev/min. Note 2- Temporary governing cannot be carried out on hydraulic dynamometer. It may be done on rope brake dynamometer.


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Section IV: Certification Criteria Identification of Critical Requirements of the Indian Standard

(To be provided by CMD)


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Scheme of Testing and Inspection:

Please see next page for STI/10001/6, Dec 2010


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Marking Fee Rate:

The following rates of marking fee is applicable for a licencee:

i) Rate of Marking Fee:

Unit-1 Engine

Rs 17.3 per unit for first 1500 units and Rs.10.4 for remaining units.

ii) Minimum marking fee Rs. 29000 (for Small Scale Industries) / Rs 34000/-(for Large Scale Industries) for one operative year payable in advance which will be carried to next renewals.

iii) Actual marking fee for the first nine months of the operative period calculated on unit rate basis on the production marked or the minimum marking fee whichever is higher shall be payable by the licencee.


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Grouping Guideline:- Individual sample is to be tested for the requirements of IS 10001:1981.

Guideline for writing Scope of Licence:-

Scope of licence may be written as Performance Requirements for constant Speed Compression Ignition (Diesel) Engines for General Purposes (up to 19kW), Model No:- -- Rated out put in kW: -----, Type of IS rating:----Rated speed in rev/min:----, Specific fuel consumption g/kWh:----, Class of governing:----, Grades of oil and fuel to be used:-----, Number of cylinders:-----, Mechanical efficiency:-----, Lub. oil consumption:-----, Method of cooling:-----, Type of fuel injection:-----, No. of stroke:-----, Type of Engine:-----, as per IS 10001: 1981

Guidelines for inclusion of new varieties :-

For getting a new variety included in the existing licence, a licensee is required to get the sample of each variety tested from BIS recognized laboratories. In case. additional manufacturing and testing facilities are required to be declared for inclusion in the scope of the licence.

Sample size: -

01 Engine along with a set of design and critical components

Manner of sealing the sample:-

After packing the sample in polythene cover, sample should be preferably packed in wooden box/crates.

Whether remanants of the sample are returnable/non-returnable:

Returnable

Procedure to be followed for destroying the product that does not meet the quality parameters during regular production :

Not Applicable


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Section V: Inspection and Testing

Packing Material Requirements (to be available in factory at all times) for packing/dispatch of samples :-

Polythene cover, cotton tape, sealing wax, match box etc.

List of required test equipment/facilities with requirement and frequency of calibration:

(To be provided by Central Lab, Sahibabad)


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Status of test facilities in BIS labs and OSLs with testing charges and approximate time required for testing:-

Lab name Testing charges Approx time required for testing

PBO Lab Rs 2175/- up to 3.55 kW (5 hp) performance test

30 days

1.NSIC Technical Services Centre 80Ft. 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

-------------------------- 2. 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

Rs.15000/- 6 months

Single Cylinder Upto 8 kW for Type Test Rs.36000/- & Performance Rs.4680/- Single Cylinder above 8 KW to 20 KW for Type Test Rs.36000/- & Performance Test Rs.6840/-; Double Cylinder Upto 8 KW for Type Test Rs.43200 & for Performance Test Rs.6840/-, Double Cylinder 8 KW to 20 KW for Type Test Rs.43200/- & for Performance Test Rs.8640/- , Three Cylinder upto 20 KWfor Type Test Rs.50400/- for performance Test Rs.10440/-; Four Cylinder upto 20 KW for Type Test Rs.57600 & for Performance Test Rs.12600/-.

Single cylinder-Rs.43170/-**

Double cylinder Rs.50910/-** (25% discount for BIS). **Fuel charges and oil charges will be at actual.


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Whether grant of licence will be based on :

Factory testing basis X

Independent testing basis √

Mixed(Factory testing basis plus Independent testing basis ) X

Details of tests to be carried out in the factory in case of :

Applicant samples/verification sample- Raw material and Components, routine tests

Survelliance/Market samples- Raw material and Components, routine tests (Fuel consumption, Governing and Eight hour rating test)

Raw material samples to be got tested, if any- All Raw materials (for physical and chemical requirements) shall be got tested on lot wise basis.

draft product certification manual for comments - … · rope brake drum (in case of rope brake...

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