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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)
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BIS logo BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION
SCHEME
PRODUCT CERTIFICATION MANUAL
Diesel Engines
Doc No: Issue No: Date: Nov 2013 Page No. Prepared by: Head
(RBO) Approved by:
Amendment Sheet
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BIS logo BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION
SCHEME
PRODUCT CERTIFICATION MANUAL
Diesel Engines
Doc No: Issue No: Date: Nov 2013 Page No. Prepared by: Head
(RBO) Approved by:
FORWORD This manual elaborates principle manufacturing
processes, infrastructure and quality controls, Scheme of Testing
and inspection ,Marking fee rates, guidelines for writing scope of
licence and inclusion of new types, Size of sample to be drawn for
testing and manner of sealing it, list of test
equipments/facilities, testing charges, testing time and Test
facilities at BIS labs/OSLs etc. This also outlines raw materials
involved in manufacturing of the product. This manual aims in
providing basic inputs and all essential aspects with the
expectation of bringing uniformity in BIS certification activity of
the product. This document is intended for internal use by BIS
inspecting officers who should however do not treat such document
as replacement for referred Standards or that of relevant Scheme
for Testing and Inspection (STI).
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BIS logo BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION
SCHEME
PRODUCT CERTIFICATION MANUAL
Diesel Engines
Doc No: Issue No: Date: Nov 2013 Page No. Prepared by: Head
(RBO) Approved by:
Table of Contents
SECTION I PRODUCT Description of Product(s) Latest Indian
Standard List of Referred Indian Standards Checklist for Submission
of an application for GOL SECTION II RAW MATERIALS List of
Important Raw Materials SECTION III MANUFACTURING PROCESS &
IN-PROCESS QUALITY CONTROLS Manufacturing Process & Control
Section Infrastructure for production SECTION IV CERTIFICATION
CRITERIA Identification of critical requirements of IS 11170:1985
Scheme of testing and inspection Marking fees Guidelines for
writing scope of licence Guidelines for inclusion of new varieties
Sample Size Manner of sealing sample Handling of Remnants SECTION
IV INSPECTION AND TESTING Packing material requirement for samples
List of required Test Equipment/facilities and frequency of
calibration Status of Test Facilities in BIS Labs and OSLs with
Testing Charges, and approximate time required for testing by BIS
Labs/OSLs Basis for Grant of Licence Details of Tests to be carried
out in factory SECTION V OTHER IMPORTANT ASPECTS
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BIS logo BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION
SCHEME
PRODUCT CERTIFICATION MANUAL
Diesel Engines
Doc No: Issue No: Date: Nov 2013 Page No. Prepared by: Head
(RBO) Approved by:
SECTION I
PRODUCT DESCRIPTION
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BIS logo BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION
SCHEME
PRODUCT CERTIFICATION MANUAL
Diesel Engines
Doc No: Issue No: Date: Nov 2013 Page No. Prepared by: Head
(RBO) Approved by:
SECTION I PRODUCT DESCRIPTION
a) Product Description:
Diesel Engines Diesel Engines set is commanally used for drawing
water from the waterbed for domestic and industrial and
agricultural purposes for driving and running the machines also.
The standard IS 11170:1985 for Diesel engines sets (constant speed
compression ignition (Diesel) Engine (up to 20 kW) which was first
published in 1985. The constant speed compression ignition (Diesel)
Engine set are of two categories
1. Constant speed Diesel Engines sets for general purpose
Constant speed Diesel Engines sets for agriculture purpose
The constructs part of the Constant speed Diesel Engines sets
essentially consists of the following:
a) Crank case b) Cam shaft bush c) Tapper roller bearing d)
Drain pipe. e) Studs f) Rocker adjustment g) Fulcrum pine h) Gear
cover plate i) Nuts and buts of different sizes j) Plane washer k)
Main bearing housing l) Gasket and seals m) Joint for cover plate
n) Oil deflector o) Oil seal p) Fuel pump bracket q) Fuel pump
tapped r) Spring washer s) Fuel pump rocker lever t) Joint Flc u)
Fuel pump rocker lever spindal v) Deep stick w) Cylinder block x)
Cylinder liner y) Liner joint ring z) Sheems aa) Water flange(in
case of water cooled diesel engine) bb) Push road cover cc)
Cylinder head
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BIS logo BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION
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PRODUCT CERTIFICATION MANUAL
Diesel Engines
Doc No: Issue No: Date: Nov 2013 Page No. Prepared by: Head
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dd) Valve rocker assembly ee) Rocker shaft ff) Spring for rocker
arm gg) Decompration shaft hh) Decompression lever ii) Knob for
decompression shaft jj) Knob for rocker box kk) Core plug for
rocker box ll) Crank shaft
mm) Flywheel nn) Flywheel key oo) Tapper roller bearing pp)
Lubricating oil pump qq) Lubricating oil strainer rr) Crank shaft
gear wheel ss) Retaining cup tt) Bearing plate uu) Balancing weight
vv) Connecting rod ww) Piston ring xx) Piston yy) Small and bush
zz) Gudgeon pin aaa) Circlip bbb) Connecting rod bolt ccc) Cam
shaft ddd) Cam shaft gear eee) Gov. push rod fff) Wall tapped ggg)
Extension shaft hhh) Gov. Weight iii) Gov. Spring jjj) Cam shaft
bush kkk) Oil seal lll) Fuel pump
mmm) injector nozal nnn) Fuel pump ooo) Speeder spring ppp) Air
cleaner qqq) Manifolds etc......
Are the essential parts of any Diesel Engine
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BIS logo BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION
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PRODUCT CERTIFICATION MANUAL
Diesel Engines
Doc No: Issue No: Date: Nov 2013 Page No. Prepared by: Head
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b) LATEST INDIAN STANDARD:
a. IS 11170:1985 Specification for performance requirements for
constant speed compression ignition (Diesel) Engines for
agriculture purposes up to (20 kW)
Amendments 1 to 5
c) List of referred standard
i) IS : 10000 (Part I) Glossary of terms relating to test
methods. ii) IS : 10000 (Part II) Standard reference conditions.
iii) IS : 10000 (Part III) Measurements for testing, units and
limits of accuracy. iv) IS : 10000 (Part IV) Declarations of power,
efficiency, fuel consumption and
lubricating oil consumption. v) IS : 10000 (Part V) Preparation
for tests and measurements for wear. vi) IS : 10000 (Part VI)
Recording of test results vii) IS : 10000 (Part VII) Governing
tests for constant speed engines and selection of
engines for use with electrical generators. viii) IS : 10000
(Part VIII) Performance tests ix) IS : 10000 (Part IX) Endurance
tests x) IS : 10000 (Part X) Tests for smoke levels, limits and
corrections for smoke levels for
variable speed engines xi) IS : 10000 (Part XI) Information
required with inquiry or order and information
supplied by the manufacture with the engine, and xii) IS : 10000
(Part XII) Test certificates
d) CHECK LIST FOR SUBMISSION OF AN APPLICATION FOR GOL
As per annexure A
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BIS logo BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION
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PRODUCT CERTIFICATION MANUAL
Diesel Engines
Doc No: Issue No: Date: Nov 2013 Page No. Prepared by: Head
(RBO) Approved by:
Section II Raw Materials and components
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BIS logo BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION
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PRODUCT CERTIFICATION MANUAL
Diesel Engines
Doc No: Issue No: Date: Nov 2013 Page No. Prepared by: Head
(RBO) Approved by: The raw material various components are as given
in the respective drawing along with the technical specification of
raw material and refer standard. It varies with the manufacturer to
manufacturer.
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BIS logo BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION
SCHEME
PRODUCT CERTIFICATION MANUAL
Diesel Engines
Doc No: Issue No: Date: Nov 2013 Page No. Prepared by: Head
(RBO) Approved by:
Section III
Manufacturing Process and In- Process Quality Control
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BIS logo BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION
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PRODUCT CERTIFICATION MANUAL
Diesel Engines
Doc No: Issue No: Date: Nov 2013 Page No. Prepared by: Head
(RBO) Approved by:
Section III
a) Manufacturing process and in process quality control
Description of manufacturing process for Diesel engine 1)
Castings/Machined components are procured from approved suppliers
as per
drawings 2) After procurement of casting and components from the
relevant parties, 100%
inspection of critical components carried out as per the
required sizes. The castings are checked for soundness with the
help of hydraulic pressure and only sound castings components are
used for assembly.
3) It is to ensure that each component of diesel engine
purchased bears a test certificate of the supplier. To ensure the
conformity of the composition, the counter check of raw material is
carried out in the outside lab and test certificates are ensured to
be available for inspection.
4) After ensuring the dimensional check the confirming machine
component are assembled and in process the various clearances
required for smooth running are ensure by petrol inspection by way
of in process quality control.
5) After assembly engines are tested as per the relevant part of
IS 10000 for the related requirement as mentioned above in relevant
standard.
b) In process quality control 1) Routine testing
Assembled engine are coupled through flexible coupling of the
Dynamometer. The Engine is allowed to warm up in the coupled
condition and run for 2 to 3 hours for warming up and stabilizing
temperature. Once the temperature stabilized load is implied on the
engine from the dynamometer in steps. And readings are taken as per
the standard.
During the testing temperature of exhaust flue gases and initial
gas
temperature is taken for the purpose of calculation. After that
the governing test is carried out by running the engine at
rated
speed, Rated output. Suddenly relieved load and check the
momentary change percentage of speed and should be ensure that it
is within the 15% and permanent change % of rated speed is within
8% of the specified rated speed for class B 1 governing.
2) All the engines which meets this specification requirements
are sent for painting
and applying of rating plates and standard marks etc... before
sending them to finish good store from where the engines are
dispatched as per the orders.
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BIS logo BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION
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PRODUCT CERTIFICATION MANUAL
Diesel Engines
Doc No: Issue No: Date: Nov 2013 Page No. Prepared by: Head
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Manufacturing flow chart for Diesel engine
Machined components purchased from vendors
Inspection of all components with requirements as declared in
the drawings
Physical and chemical test of the critical components got
done
Testing for routine test
Grinding and chipping of components wherever necessary
Sub- assembly & main assembly with intermediate checks
Painting
Packing
Dispatch
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BIS logo BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION
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PRODUCT CERTIFICATION MANUAL
Diesel Engines
Doc No: Issue No: Date: Nov 2013 Page No. Prepared by: Head
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b) Infrastructure for production The following manufacturing
facilities/ machinery are necessary for manufacturing of
submersible pump The manufacturing facilities. No manufacturing
machinery is required for manufacturing as all components are
received in machined conditions as per drawings. Only assembly
tables – tools likes spanner, mallet and torque wrench are required
in assembly.
c) In process quality control 1. Cast iron components are
checked towards casting defects 2. All machine components are
verified as per the drawings and sizes 3. The free running of
piston in cylinders checked and assembly checks are carried
out during manufacturing and assembly of Diesel engine sets. 4.
Fly wheel balancing is done. 5. Hydraulic testing is carried out on
components like cylinder head, cylinder liner
etc... before assembly.
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BIS logo BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION
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PRODUCT CERTIFICATION MANUAL
Diesel Engines
Doc No: Issue No: Date: Nov 2013 Page No. Prepared by: Head
(RBO) Approved by:
SECTION IV Certification Criteria
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BIS logo BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION
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PRODUCT CERTIFICATION MANUAL
Diesel Engines
Doc No: Issue No: Date: Nov 2013 Page No. Prepared by: Head
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SECTION IV Certification Criteria
a) Identification of critical requirements of the Indian
standard
Note: To be provided by CMD
b) Scheme of Testing and Inspection Enclosed as annexure B
c) Marking fee rates Description Value
Unit 1 ENGINE L S Marking Fee 34000 S S Marking Fee 29000 Slab 1
Rate 17.3 Slab 1 Qty 1500 Slab 2 Rate 10.4 Slab 2 Qty Rest Slab 3
Rate 0 Enforcement Date 20120806 Remarks
d) Grouping guidelines
There is no grouping guidelines for Diesel engine as per IS
11170:1985.
e) Guidelines for scope of writing
While writing the scope of Diesel engine followings points are
to be kept in consideration
1) Model No is mentioned 2) Diesel engine type horizontal or
vertical – Type of cooling- water
cooled or air cooled, power rating - RPMs – SFC – IS rating –
Governing class – lubricating oil consumption - lubricating oil
specification – type of bearings – type of piston – balancing type
– injection type i.e. direct or indirect – fuel type – fuel
consumption are to be specified.
f) Guidelines for Inclusion of new variety There is no
guidelines for Inclusion of new variety Diesel engine as per IS
11170:1985 in existing licence.
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BIS logo BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION
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PRODUCT CERTIFICATION MANUAL
Diesel Engines
Doc No: Issue No: Date: Nov 2013 Page No. Prepared by: Head
(RBO) Approved by:
g) Sampling Plan
Sampling plan to be followed as as per the STI given by CMD
h) Manner of sealing of samples As per the prevailing practice
at RBO, the samples are signed by IO, then they are sealed with
sealing wax and brass seal/ lead seal The code number is written on
the tag as well as on the Diesel Engine.
i) Remnants Since Diesel Engine is costly item remnants of the
Diesel Engine after testing are returned to the
licensee/applicant.
j) Procedure to be followed for destroying/ reshaping/ recycling
the Non confirming products
In Diesel Engine, the Diesel Engine which do not meet the
requirements are normally sold without BIS standard Marks or
reassembled after changing the components found defective/ or
effecting the efficiency of Diesel Engine i.e. piston assembly or
cylinder head and piston gap etc.... depending on the situation
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BIS logo BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION
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PRODUCT CERTIFICATION MANUAL
Diesel Engines
Doc No: Issue No: Date: Nov 2013 Page No. Prepared by: Head
(RBO) Approved by:
SECTION V INSPECTION AND TESTING
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BIS logo BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION
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PRODUCT CERTIFICATION MANUAL
Diesel Engines
Doc No: Issue No: Date: Nov 2013 Page No. Prepared by: Head
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SECTION V INSPECTION AND TESTING
a) Packing material requirements (to be available in factory at
all times) for
packing/ Dispatch of samples
No Packing material required for packing of Diesel Engine set
sample. Since no packaging material is required for Diesel Engine,
additional material to be available with the firm at the time of
inspection or for sealing of sample following material is
required.
1) Self adhesive stickers for making the tags to be a fixed on
motor and submersible pump.
2) Brown labelling tags to be a fixed with the packaging
material. 3) Sealing wax 4) Thread for tieing sealing wax and seal
for dispatch of sample to independent lab.
b) List of test equipment facilities with requirements and
frequency of
calibration
This detail is to be provided by CL.
c) Status of Test facilities in BIS lab/ OSL
List of BIS Laboratories
Lab Quantity Lab Type
Testing Facility Remarks
IS Number :- IS 11170 - 0 : 1985
PBOL 1no. Mech P Performance test only, Rating 5.9 kw,1500/1600
rpm
IS No. Testing Charges
Remarks
IS 11170 : 1985 Rs 24825/- 3.55 kW
Testing Facility:: C=Complete Test facility / P=Partial Test
Facility/ N=No Test Facility
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BIS logo BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION
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PRODUCT CERTIFICATION MANUAL
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Doc No: Issue No: Date: Nov 2013 Page No. Prepared by: Head
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List of Outside Recognized Laboratories
IS Number :- IS 11170 - PERFORMANCE REQUIREMENTS FOR CONSTANT
SPEED COMPRESSION IGNITION (DIESEL) ENGINES FOR AGRICULTURAL
PURPOSES (UP TO 20
KW)
Sl No.
Name of the Recognized Laboratory Lab Code Testing Charges
Remarks
1 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 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 KW for
Type Test Rs.50400/- & for performance Test Rs.10440/-; Four
Cylinder upto 20 KW for Type Test Rs.57600 & for Performance
Test Rs.12600/-
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
7101125 Single cylinder- Rs.43170/-**, Double cylinder-
Rs.50910/- ** [25% discount for BIS]
** Fuel charges and oil charges will be at actuals.
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BIS logo BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION
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PRODUCT CERTIFICATION MANUAL
Diesel Engines
Doc No: Issue No: Date: Nov 2013 Page No. Prepared by: Head
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Basis of Grant of Licence The Grant of Licence in case of Diesel
engine is granted based on the
independent test report only.
d) Details is tests to be carried out in the factory in case of:
1) Applicant/verification samples- Complete testing as per IS
11170:1985 for is
possible. 2) Surveillance/ Market samples- loop test as per IS
11170:1985 is possible. 3) Raw material samples to be got tested:
form outside lab NABL approved lab and
verification of test certificates from manufacturer as well as
cross conformity test got done by the firm.
4) Drawings to be checked for verification of components and to
be supplied a copy of complete set to the lab for checking of wear
and tear limits during the performance test.
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