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MINISTRY OF DEFENCE
JOINT SERVICES SPECIFICATION
ON
HOSE ASSEMBLY, RUBBER SUCTION,
ARMOURED, HEAVY DUTY
(DS CAT NO. 4210-000 546)
MANAKIKARAN NIDESHALAYA
RAKSHA UTPADAN TATHA POORTI VIBHAG
RAKSHA MANTRALAYA, 'H' BLOCK, DHQ PO
NEW DELHI - 110 011
DIRECTORATE OF STANDARDISATION
DEPARTMENT OF PRODUCTION & SUPPLIES
MINISTRY OF DEFENCE, 'H'- BLOCK, DHQ PO
NEW DELHI - 110 011
ON
MANAKIKARAN NIDESHALAYA
RAKSHA UTPADAN TATHA POORTI VIBHAG
RAKSHA MANTRALAYA, 'H' BLOCK, DHQ PO
NEW DELHI - 110 011
DIRECTORATE OF STANDARDISATION
DEPARTMENT OF PRODUCTION & SUPPLIES
MINISTRY OF DEFENCE, 'H'- BLOCK, DHQ PO
NEW DELHI - 110 011
i
The following members were present/ consulted in approving the document:Name and Designation
Organisation
ii
Date
Amendment
pertains to :
Sl. No./Para No./
Column No.
Authority
Amended by
Name & Appointment
(IN BLOCK LETTERS)
iii
Signature
&
Date
FOREWORD
1.
SCOPE
2.
RELATED SPECIFICATIONS
3.
STANDARD PATTERN
4.
MATERIAL
5.
MANUFACTURE/ CONSTRUCTION
6.
7.
MARKING
8.
9.
QUALITY ASSURANCE
10.
WARRANTY
11.
PACKAGING
12.
13.
14.
APPENDIX 'A'
10
iv
FOREWORD
0.1
This Joint Services Specification has been prepared by Engineering Equipment
Standardisation Sub Committee on the authority of the Standardisation Committee,
Ministry of Defence.
0.2
This specification has been approved by the Ministry of Defence and is
mandatory for use by the Defence Services.
0.3
This specification has been prepared based on Defence Specification
IND/CQAFE/PROV/0059(b) and supersedes the same.
0.4
This specification shall be used to guide design, manufacture, quality assurance
and procurement of Hose Assembly, Rubber Suction, Armoured, Heavy Duty, Complete
with Screw Couplings used in Trailer/ Truck Fire Fighting & Crash Fire Tender.
0.5
Quality Assurance Authority for the item covered by this specification is
CQA(FE), Pune for Army, Navy and Air Force being inter service AHSP. Enquiries
regarding this specification relating to any contractual conditions should be addressed to
the Quality Assurance Authority named in the tender or contract. Other enquiries should
be referred to :The Director,
Directorate of Standardisation,
Ministry of Defence,
`H' Block, DHQ PO,
New Delhi - 110 011.
0.6
0.7
This specification holds good only for the supply order for which it is issued.
SCOPE
1.1
This specification relates to manufacture, construction and quality assurance of
Hose Assembly, Rubber Suction, Armoured, Heavy Duty, Complete with Screw
Couplings.
2.
RELATED SPECIFICATIONS
2.1
IS 280:1978
(b)
IS 318:1981
(c)
IS 443:1975
(d)
IS 902:1992
(e)
IS 937:1981
(f)
IS 3400(Part 1):1987
(g)
IS 3400(Part 4):1987
2.2
IS 3549:1983
Copies of the Indian Standards are obtainable on payment from :Bureau of Indian Standards,
Manak Bhavan,
9, Bahadur Shah Zafar Marg,
New Delhi - 110 002.
or
their regional/branch offices
3.
STANDARD PATTERN
3.1
The Standard Pattern, if held with purchasing or Quality Assurance Authority,
may be referred and shall constitute a general guide only. The stores shall conform to this
specification otherwise.
3.2
4.
b)
c)
MATERIAL
4.1
Material used for the manufacture of Hose Assembly, Rubber Suction, Armoured,
Heavy Duty shall be of the highest grade and shall conform to the latest relevant
specification.
4.2
Hose Assembly, Rubber Suction, Armoured, Heavy Duty shall be manufactured
from the following materials:
4.2.1
Hose Rubber
4.2.1.1 Lining and Cover: The lining and cover shall be made from a suitable rubber
compound conforming to the requirements of Clause 4.6 and 4.7 of IS 3549 and shall be
free from air blisters, porosity or any other visible defects.
3
MANUFACTURE/CONSTRUCTION
5.1
The bore size of hose (nominal size 75 mm & 100 mm) when measured according
to the method prescribed in Clause 4.2.1.2 of IS 443 shall not vary more than 2.0 mm.
5.2
Thickness of lining filler and cover: The thickness of lining filler and cover
when measured according to the method prescribed in Clause 4.2.2 of IS 443 shall not be
less than that specified in Table 2 of IS 3549.
5.3
The dimensions/tolerances of coupling screw male and female (nominal size 75
mm & 100 mm) shall be conforming to IS 902.
5.4
Length
5.4.1 Hose Assembly, Rubber Suction, Armoured, Heavy Duty, Complete with Screw
Couplings shall be supplied in lengths of 2.5 m, 3 m and 4.5 m which includes the length
of soft end portions of the hose.
5.4.2 The length of the soft ends (ends free of wire) for hoses having nominal bore 75
mm and 100 mm shall be 100 5 mm and 125 5 mm respectively.
5.4.3 Tolerance on length of hose assembly, complete with couplings shall be + 2%, 1% and for this purpose the length shall be measured before the hose is subjected to
hydraulic pressure test.
5.5
Construction
5.5.1 Hose Rubber: Hose Rubber shall be constructed conforming to Clause 4.5.2 and
Clause 4.5.3 of IS 3549.
4
5.5.3 Couplings shall be securely tied into enlarged ends of hose by means of
galvanised mild steel wire of 2 mm dia in close spacing. The shanks of the couplings
shall fit into the end of the hose to their full length. The binding wires shall then be
wound tightly over the ends of the hose covering the shanks making the joints water tight.
After binding the loose ends shall be turned in and the entire binding shall be soldered
along the place where the ends are turned in.
6.
6.1
Hose rubber shall be free from air blisters, porosity and other surface defects.
Couplings shall not have sharp edges. The water way shall have smooth finish. Wire
binding shall be done properly so that both the coupling screw do not come out from the
hose during use. Also, there should be no leakage while in use.
7.
MARKING
7.1
The Hose and Coupling shall be marked as per details given below:a)
Nomenclature:
i)
On Hoses
Complete nomenclature
indicating size
ii)
On Couplings
b)
DS Cat No.
c)
d)
To be marked on Hoses as
well as on Couplings
PRE-INSPECTION OF STORES/CONSIGNMENT
8.1
Manufacturers/suppliers shall satisfy themselves that the stores are in accordance
with the terms of the contract and fully conform to this specification by carrying out a
thorough pre- inspection of each lot before actually tendering the same for inspection to
the Quality Assurance Officer nominated under the terms of the contract. A declaration
by the contractor that necessary pre-inspection has been carried out on the stores
tendered, will be submitted alongwith the challan. The declaration will also indicate the
method followed in carrying out pre-inspection showing the feature checked/tested and
will have the test certificate attached to the challan/declaration.
8.2 If the Quality Assurance Officer finds that pre- inspection of the consignment as
required above has not been carried out, the consignment is liable for rejection.
9.
QUALITY ASSURANCE
9.1
The contractor shall extend to the Quality Assurance Authority or his authorised
representative, free of cost, all reasonable facilities for inspection and testing of stores
including inspection gauges for satisfying themselves that the stores are manufactured in
accordance with this specification and subcontractors premises at all times during run of
contract. The contractor shall notify to the Quality Assurance Authority, of all subcontract placed by him and provide inspection facilities for all stores so sub-contracted.
9.2
No deviation shall be accepted from the governing design and specification
without concurrence in writing of the Quality Assurance Authority. The contractor shall
remain responsible for quality/ quantity in any fabrication done by the subcontractors.
9.3
Detailed test schedule shall be followed as per the procedure given in Appendix
`A' attached with this specification.
9.4
The store shall be inspected at the supplier's premises for satisfactory performance
and proper packaging before despatch to the consignee.
9.5
Advance Sample
9.5.1 One advance sample of Hose Assembly, Rubber Suction, Armoured, Heavy Duty,
Complete with Screw Couplings of the required size duly wire bound together with
rubber compound, test slabs of sizes 300 x 300 x 2.5 mm and 150 x 150 x 6.5 mm,
used for Washer and 3 m each of Reinforcement Wire and Binding Wire shall be
submitted to the Controller, CQA(FE), Pune-27 for test and approval before
commencement of bulk production.
Performance Test
9.6.1 Couplings: Before wire binding both male and female couplings shall be
subjected to hydraulic pressure of 21 kgf/cm2 for a period of 2 minutes as per Clause 8 of
IS 902 and shall not show any sign of leakage or failure at the end of test.
9.6.2 Tensile Strength and Elongation at Break: This shall be tested on rubber
compound used on lining/ filler/ cover conforming to Clause 4.6 of IS 3549 i.e. Tensile
Strength and % Elongation at Break shall not be less than 7.0 MN/m2 and 300%
respectively when tested according to method prescribed in Clause 5 of IS 443.
9.6.3 Accelerated Ageing Test: This shall be carried out on rubber compound on
lining/ filler/ cover conforming to Clause 4.7 of IS 3549 and shall not vary by more than
+10%, -15% for tensile strength and percentage Elongation at break of corresponding
value obtained before ageing.
9.6.4
9.6.4.1 When tested at designed working pressure of 0.7 MPa for 5 minutes, in
accordance with clause 8.3 of IS 443, it shall not show any leakage or failure at the end of
test.
9.6.4.2 Elongation of nose at its designed working pressure shall be tested conforming to
Clause 4.8.1 of IS 3549. It shall not exceed 7.5 % of its original length measured at 0.07
MPa hydraulic pressure.
9.6.4.3 Proof Pressure Test: This shall be tested to 1 times (one and half times) the
design working pressure i.e. 1.05 MPa as per Clause 4.8.2 of IS 3549 for a period of
1 minute without any failure/ damage to the hose.
9.6.4.4 Burst Pressure Test: This shall be tested conforming to Clause 4.8.3 of IS 3549.
Hose shall not burst till the pressure is 3 times, the design working i.e. at 2.1 MPa.
9.6.4.5 Resistance to Vacuum: This shall be tested as per Clause 4.9 of IS 3549, when
tested under vacuum of 83 kPa (approximately 625 mm of mercury) hose should not
collapse. In case of smooth bore Hose, there shall not be any separation of the ply and the
lining.
WARRANTY
10.1 The stores supplied shall bear a warranty as per contract. In absence of such
mention, the following warranty shall apply.
" The stores supplied against this specification shall be deemed to bear a warranty of the
contractor against defective design, material, workmanship and performance for a period
of 12 months from the date of receipt of stores by the consignee. During this period, if
any of stores is found to be defective by the consignee, the same shall be replaced by the
supplier, free of any charges at the consignee`s end but not later than 3 months from
receipt of such intimation."
11.
PACKAGING
11.1 The store shall be delivered in new, clear, dry and sound condition duly preserved
with french chalk and only the accepted stores duly stamped with Acceptance Mark shall
be packed as per details given below:"Each length of Hose connected with Screw Couplings duly preserved shall be
completely wrapped spirally with double layer of 15 cm strip of cloth Hessian Medium
with sufficient over lapping after providing cushioning material at both the coupling
ends, so as to prevent any damage during transit. The overlapped portion of the Hessian
Cloth shall be securely stitched with double 3 Ply Jute Twine with not less than
12 stitches per decimeter, taking care not to pierce the Hose during stitching."
NOTE: The packing material to be used for packing shall be got approved by the
Quality Assurance Officer.
11.2 Before despatch, each package shall be legibly marked with indelible ink or paint
showing the following details:i)
ii)
iii)
iv)
v)
vi)
Vii)
viii)
12.1
The Defence Store Catalogue Numbers allotted to the store are as follows:-
i)
ii)
iii)
iv)
v)
vi)
Nomenclature
Hose Assembly Rubber
Suction Armoured
-do-do-do-do-do-
DS Cat/Part No.
4210-002 580
75 mm x 3 m
75 mm x 4.5 m
100 mm x 2.5 m
100 mm x 3 m
100 mm x 4.5 m
4210-002 637
4210-002 581
4210-002 582
4210-002 636
4210-002 583
13.
13.1
Test
VISUAL EXAMINATION: 100%
a) Each length of hose connected with coupling
screw, one end male and other end female, duly
wire bound of required size against the order shall
be checked visually for any material defects, like
porosity blow hole, scales, cracks on the outer/
inner surfaces of the couplings and hose. Any
other deformities/ damages to the parts and
fitment shall also be checked.
Remarks
It shall be free from all defects.
The water way shall have
smooth
b) Marking : 100%
The store shall be marked/ stamped with all the
details as per clause 7 of this specification.
2.
MATERIAL
Material should conform to
clause 4 of the specification
requirement.
10
Sl. No.
3.
Test
Remarks
DIMENSIONAL TEST
The hose rubber selected at random from the lot
shall be tested for dimensions of the following
components: a) Hose: The bore size and thickness shall be The dimensions shall be
strictly as per the specification
measured in accordance with the method.
requirement
Inter
change
Described in Clause 4.2 of IS 443
ability shall be checked with
gauges sampling as per Table 1
of IS 443
b) Coupling screw (with enlarged end & shanks) Same sampling plan i.e. Table
shall be checked as per IS 902
1 of IS 443 adopted for Hose
be also adopted for Male
Coupling, Female Nut and
Washer.
4.
-do-
11
Test
Remarks
d) Hydrostatic Test
i) All the hoses on order shall be tested at No sign of leakage from hose
designed working pressure (0.7 MPa) as per coupling or wire binding shall
be observed.
Clause 9.6.4.1 of this specification.
ii) While testing hose as per (i) above elongation Change in length shall not
at designed working pressure shall be checked as exceed 7.5% of its original
length measured at 0.07 MPa
per Clause 9.6.4.2 of this specification.
hydraulic pressures.
iii) Proof Pressure Test
Hose assembly shall be checked as per Clause It should withstand the proof
test pressure for one minute
9.6.4.3 of this Specification.
without any failure or damage
to the hose. Sampling as per
Table I of IS 443.
12
Sl. No.
Test
Remarks
e) Resistance to Vacuum
Qty one number of hose fitted with couplings
from each lot should be tested in accordance with
the method prescribed in Clause 14 of IS 443
under vacuum of 83 KPa (625 mm of mercury
approximately)
5.
13