DOC:STI/778/4

November 1986

SCHEME OF TESTING AND INSPECTION FOR

CERTIFICATION OF
COPPER ALLOY GATE, GLOBE AND CHECK VALVES FOR
WATER WORKS PURPOSES
ACCORDING TO IS 778:1984

1 LABORATORY - A laboratory shall be maintained which shall be suitably equipped

and staffed, where different tests given in the specification shall be carried out.

1.1 The testing equipment shall be periodically checked calibrated and records of all such
checks calibrations shall be maintained.

1.2 TEST RECORD - The thread gauges shall be calibrated after every 5000 applications
or one in three years whichever is earlier.

2. All records of tests shall be kept in suitable forms approved by the Institution.

2.1 Copies of any records or charts that may be required by the Institution shall be made
available at any time on request.

2.2 It is recommended that, as far as possible, Statistical Quality Control (SQC) methods
may be used for controlling quality during production as envisaged in this scheme {See IS 397
(Part 1)-1972, IS 397 (Part II) 1975) and IS 397 (Part III)-1980}.

3. MARK - The Standard Mark, as given in Column (1) of the first schedule of the licence
shall be punched or cast on each valve, i.e. Gate valve, Globe Valve or Check Valve provided
always that the valve thus marked conforms to every requirements of the specification.

4. In addition, each valve shall be cast or stamped on the body with the following
information:

a) Manufacturers name or his recognized trade mark,

b) Class, 1 or 2, as applicable;
c) Nominal Size;
d) An arrow showing direction of flow in the case of Globe Valves and Check
Valves;
e) Identification in code or otherwise to enable to trace back the date of casting to
factory test records (may be stamped) and
f) Made in India, if required.

4.1 The information relating to type of valve as given in cl. 5 of IS 778:1984 shall be
supplied with the valves.
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November 1986

5. LEVELS OF CONTROL - The tests as indicated in Table 1 attached and at the levels
of control specified therein shall be carried out on all raw materials components and the finished
production on the whole production of the factory which is covered by this Scheme and
appropriate records and charts maintained in accordance with paragraph 2 above. All the
production which conforms to the Indian Standard and covered by this licence shall be marked
with ISI Certification Mark.

6. MATERIALS -The material for component parts of valves shall conform to

requirements given in Table 1 of IS 778:1984.

6.1 Test Bars/samples and criteria for acceptance shall be as specified in relevant
specification referred to in Table 1 of IS 778:1984.

6.2 CHEMICAL COMPOSITION - One sample for each heat/melt of Ingots shall be tested
for chemical analysis. In cast Ingots are received with suppliers test certificate, the testing may
be restricted one sample in a quarter. From the castings one sample may be tested for chemical
analysis for 1000 kg or part thereof of the castings.

6.3 TENSILE TEST Three tensile test pieces shall be separately cast, alongwith castings
for every 1000 kg of castings. One piece should be tested for tensile test. If it passes, the lot of
casting maybe accepted. In case of failure, two further test pieces representing the same lot of
castings maybe tested in the same manner. If both pieces pass the lot may be accepted, otherwise
rejected.

7 DESIGN AND MANUFACTURE - Design manufacture and dimensions of

components parts including bolts, nuts and threads on stem and valves shall conform to
requirements given in Column 7 and Column 8 and table 2 to 12 of IS 778:1984.

7.1 Except Gates for Gate Valves all other essential parts which are subject to wear shall be
interchangeable for the same size and type of valve of same manufacturer.

7.2 Bolts and nuts shall conform to IS 1367(Parts):1979/1980.

7.3 Threads on the stem shall be of the square or trapezoidal form preferable conforming to
IS 4694:1968, IS 7008(Part-III):1973 and IS 7008(Part-IV):1973, Stem of 8mm and 10mm size
valves may have screw threads conforming to IS 4218(Part-III):1967 and IS 4218(Parts-IV):1967.

8. HYDROSTATIC TEST ON BODY AND SEATS - Each valve shall be tested for
hydrostatic pressure test in accordance with clause 9.3 to 9.5 of IS 778:1984. If any valve fails in
this test, the valve should be rejected for the purpose of ISI Certification Mark.

9. In respect of all other clauses of the specification and at all stages of manufacture the
factory shall maintain appropriate controls and checks to ensure that their product conforms to the
various requirements of these clauses.

10. A record shall be maintained giving information regarding rejection of valves which do
not conforms to the specification and method of their disposal. Such valves, shall in no case be
stored with those conforming to the specification.

11. The licensee shall supply, free of charge, the samples required in accordance with the
Bureau of Indian Standards (Certification) Regulations, from his factory or godown. BIS shall
pay for the samples taken by it from the open market.
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November 1986

12. Whenever a complaint is received soon after the goods with the Standards Mark
have been purchased and used, and if there is adequate evidence that the goods have not been
misused, defective goods or their components 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 Standards
shall be with the institution.

13. The marking of the product shall be stopped under intimation to the BIS if, at any time,
there is some difficulty in maintaining the conformity of their product to the specification or the
testing equipment goes out of order, or if directed to do so by BIS for any reason. The marking
may be resumed as soon as the defects are removed or when BIS gives the permission to do so.
The information regarding resumption of marking shall also be sent to the institution.

14. The licensee shall send to the institution as per the enclosed proforma, a statement of
quantity produced, marked and exported by him and the trade value thereof for each year of
operation of the Licence. This statement should be sent twice a year, that is six months and one
year after the grant/renewal of the Licence.

Table 1...
 DOC:STI/778/4
November 1986

IS 778:1984
COPPER ALLOY GATE, GLOBE AND CHECK VALVES FOR
WATER WORKS PURPOSES
TABLEL 1 LEVELS OF CONTROL
(Para 5 to 9 of the Scheme of Testing and Inspection)

TEST DETAILS LEVELS OF CONTROL

Clause. Requirements Test Method No. of Frequency REMARKS
Clause Reference Samples
6.1 &
Materials
Table 1
i) Cast Iron IS 210:1978
a) Chemical
One
Composition Each Melt/
See cl.6.2 of STI.
b) Tensile Test 3 Tensile Bars Heat of 1000 kg. or part
See cl. 6.3 of STI.
3 Hardness Test thereof
c) Hardness Test
pieces
IS 3488:1966 If a test certificate indicating conformity to the
ii) Extruded/High Adequate number
IS 319:1974 requirements is obtained, testing by licensee
Tensile/Forged of samples to be Each consignment
IS 320:1980 maybe restricted to once in three months as
Brass drawn and tested
IS 6912:1973 counter checks.
iii) Leaded Tin IS 318:1981
Bronze/Brass IS 1264:1981
Ingots
a) Chemical In cast a test certificate indicating conformity of
One
Composition the ingots to specification is received, counter
checking may be done only once in three
Each Heat/Melt of 1000
months as counter checks. In case test
kg or part thereof
b) Tensile Test 3 Tensile Bars certificate is not available, the level of control
shown should be followed. See also clause 6.2
& 6.3 of STI
iv) Chromium IS 4389:1972
Steel
a) Chemical
One -do- -do-
Composition
b) Tensile Test 3 Tensile Bars
3 Hardness Test
c) Hardness Test
pieces
 DOC:STI/778/4
November 1986
IS 778:1984
COPPER ALLOY GATE, GLOBE AND CHECK VALVES FOR
WATER WORKS PURPOSES
TABLEL 1 LEVELS OF CONTROL
(Para 5 to 9 of the Scheme of Testing and Inspection)

TEST DETAILS LEVELS OF CONTROL

Clause Requirements Test Method No. of Frequency REMARKS
Clause Reference Samples
IS 2712:1971 If a test certificate indicating conformity to the
requirement is obtained testing by licensee may
v) Gasket Three Each consignment
be restricted to thrice in a year as counter
check.
vi) Gland packing IS 5414:1969
-do- -do- -do-
Weight/Size IS 4687:1980
Design, Cl.7 & 8 IS 778:1984
manufacture and Tables 2
dimensions and to 12
Gauges (Go, No-
workmanship:
Go Plug, Snap,
Valve bodies
thread) templates,
bonnets stuffing
micrometers,
7&8 box, Gland, Body Each component Refer Cl.7 of STI
vernier calipers,
seat, stem, Wedge
depth gauge etc.
Disc assembly (For
and visual
Globe valves), Disc
examination.
(For check valves)
back seat,
Handwheel
Body, Test 9.3 & IS 778:1984
9.3 All Each Valve
(Hydrostatic) Table 13
9.4 & -do-
9.4 Back seat test -do- -do-
table 13
Seat test 9.5 & -do-
9.5 -do- -do-
(Hydrostatic) Table 13
12.1 to IS 778:1984
12 Preparation/dispatch -do- -do-
12.4