Master Wi PDF

BENGAL INDUSTRIES PVT LTD, FARIDABAD
WORK INSTRUCTIONS
ISSUE NUMBER 04
ISSUED ON 21.03.2006
Controlled Copy Serial Number
Controlled Copy Holder Mr.

WORK INSTRUCTIONS WI:II
PAGE 1 OF 2
TITLE: TABLE OF CONTENTS REV. NO. 02 DATE-30.04.08
S.NO. Title WI No.

1. Title cover page WI:I:00
2. Table of contents WI:II:10
3. Revision record sheet WI:111:00
4. List of holders WI:IV:00
5. List of abbreviation WI:V:01
6. Pliable Test WI:QA:01:00
7. U bend Test and cantilever bend test WI:QA:02:00
8. Elongation and Burst Pressure test WI:QA:03:00
9. Leak Test WI:QA:05:00
10. Hydraulic Pressure Test WI:QA:06:00
11. Erichsen cupping test WI:QA:07:00
12. Dye penetration test WI:QA:08:00
13. Radioactive contamination test WI:QA:09:00
14. Helium Leak test WI:QA:10:00
15. S.S coil specification WI:RM:01:00
16. S.S Strip specification WI:RM:02:00
17. S.S House Specification WI:RM:03:00
18. S.S wire specification WI:RM:04:00
19. Specification for packing WI:RM:05:00
20. Specification for welding filler rods WI:RM:06:00
21. Sampling plan WI:GEN:01:00
22. Corrugating Machine operating parameters WI:GEN:02:00
23. Tube Welding WI:GEN:03:00
24. Preventive Maintenance-Corrugating machine 1&2 WI:GEN:04:00
25. Preventive Maintenance-Tube forming & welding WI:GEN:05:00
machine
26. Assembly Welding WI:GEN:06:00
27. Hose to Hose Welding WI:GEN:07:00
28. Specifications of bobbin winding WI:GEN:08:00
29. Specification of corrugating machines WI:GEN:09:00
30. Specifications of coil slitting WI:GEN:10:00
31. Specifications of braiding Machine WI:GEN:11:00
32. Preventive maintenance of lathes WI:GEN:12:00
33. Preventive maintenance of D.G. sets WI:GEN:13:00
34. Preventive maintenance of milling machine WI:GEN:14:00
35. Preventive maintenance of arc welding set WI:GEN:15:00
Approved by Controlled by Issued by Issue:04 Effective date

21.03.2006
PAGE I OF 2
TITLE: TABLE OF CONTENTS REV. NO. 02 DATE-30.04.08
S.NO. Title WI No.

36. Preventive maintenance of drilling machine WI:GEN:16:00
37. Preventive maintenance of bobbin winding machine WI:GEN:17:00
38. Preventive maintenance of braiding machine WI:GEN:18:00
39. Operating instructions of bobbin winding machine WI:GEN:19:00
40. Operating instructions of corrugating machine WI:GEN:20:00
41. Operating instructions of braiding machine WI:GEN:21:00
42. Operating instructions of tube mill WI:GEN:22:00
43. Maintenance of compressors WI:GEN:23:00
44. Operating instructions of ultrasonic cleaning system WI:GEN:24:00
45. Operating instructions of mechanical corrugators WI:GEN:25:00
46. Authorized persons for quality related activities WI:GEN:26:00
47. Operating instructions of tubemill-2 WI:GEN:27:00
48. Assembly of composite hoses WI:GEN:28:00
49. Swaging instructions WI:GEN:29:00
50. Type of composite hose and their applications WI:GEN:30:00
51. Color coding of composite hoses WI:GEN:31:00
52. Epoxy mixture preparation for composite hose assemblies WI:GEN:32:00
53. Hydrostatic test for composite hose assemblies WI:GEN:33:00
54. Electrical continuity resistance test for composite hose WI:GEN:34:00
assemblies
55. Determination of suction resistance of composite hose WI:GEN:35:00
assemblies
56. Determination of bend radius of composite hose assemblies WI:GEN:36:00
57. Braiding specification for flex connector WI:GEN:37:00
58. Coil slitting specification for flex connector WI:GEN:38:00
59. Tube welding test equipment WI:GEN:39:00
60. Braid folding and cutting machine WI:GEN:40:00
61. Operating instructions of Interlock forming machine-1 WI:GEN:41:00
62. Instrument storage, preservation & safe guarding WI:GEN:42:00
63. D.M water testing WI:GEN:43:00
64. Specification for Interlock WI:GEN:44:00
65. Operating instructions of Interlock forming machine-2 WI:GEN:45:00
66. Operating instructions of shearing machine WI:GEN:46:00
67. Operating instructions of weld seamer ws-450 machine WI:GEN:47:00
68. Operating instructions of seamer ws-1500 machine WI:GEN:48:00
69. Deburring WI:GEN:49:00
70. Deterioration control WI:ST:01:00
71. Drawing control WI:DRG:01:00
72. Hindi versions of WI:QA:07,WI:GEN:06, 07, 19, 20,21,22
73. WI FOR CNC & VMC M/C WI:GEN:49:00
21-03-2006

PAGE I OF 2
TITLE: REVISION RECORD SHEET REV. NO. 01 DATE-1-1-2007
S.NO. WI No. Rev. No. Date of Rev. Nature of amendment

1 WI:GEN:09 01 10.12.2006 Standard and heavy series hose
specs added
2. WI:GEN:10 01 10.12.2006 Standard and heavy series hose
specs added
3. WI:II 01 1.1.2007 Table of contents
4. WI:III 01 1.1.2007 Revision record sheet
5. WI:GEN:11 01 1.1.2007 Standard and heavy series braid
specs added
6. WI:GEN:08 01 1.1.2007 Standard and heavy series braid
specs added
7. WI:GEN:37 01 1.1.2007 Braid specs for car flex added
8. WI:GEN:38 01 1.1.2007 Coil specs for car flex added
9. WI:GEN:39 01 1.1.2007 Tube welding test equipment added
10. WI:QA:04:00 Removed from list
11. WI:GEN:40 00 Work instruction for braid folding
and cutting machine added
12. MLD:01 00 Master list of drawings added.
13. WI:GEN:41:00 00 Work instruction for interlock
forming added
14. WI:GEN:42:00 00 Work instruction for storage,
preservation & safeguarding of
instrument added
15. WI:GEN:43:00 00 Work instruction for D.M water
testing added
16. WI:GEN:44:00 00 Specification for Interlock added
17. WI:GEN:45:00 00 Operating instructions of Interlock
forming machine-2 added
18. WI:GEN:46:00 00 Operating instructions of shearing
machine added
19. WI:GEN:47:00 00 Operating instructions of weld seamer
ws-450 machine added
20. WI:GEN:48:00 00 Operating instructions of seamer ws-
1500 machine added

21-03-2006
PAGE 2OF 2
TITLE: REVISION RECORD SHEET REV. NO. 01 DATE-1-1-2007
S.NO. WI No. Rev. No. Date of Rev. Nature of amendment

22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
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42.

21-03-2006
WORK INSTRUCTIONS WI:IV
PAGE I OF 1
TITLE: LIST OF HOLDERS REV. NO. 00 DATE-
COPY S.NO. CONTROLLED COPY HOLDER DEPARTMENT

1. Director ----
2. AGM --
3. AGM (production) / M.R Production
4. Sr.Manager Quality assurance
WORK INSTRUCTION No. PLACE

WI:Q.A.:01-07 Shop floor in English
WI:RM:01-06 A.G.M (C&A)
WI:GEN:3,6,7,8,9, 10&11 Shop floor in English
WI:ST:01 Stores
WI:GEN:6,7,19,20,21,22 Shop floor in Hindi
WI:Q.A.:07 Shop floor in Hindi

21-3-2006
PAGE I OF 1
TITLE: LIST OF ABBREVIATION REV. NO. 00 DATE-
S.NO. ABBREVIATION DETAILS

1. QA QUALITY ASSURANCE
2. M Pa Mega Pascal
3. Dia Diameter
4. Mm Millimeter
5. I.D. Internal diameter
6. O.D. Outside diameter
7. DN Nominal diameter
8. SAIL Steel Authority of India ltd
9. TC Test Certificate
10. T.S Tensile strength
11. S.S Stainless steel
12. DM De- mineralized
13. NB Nominal bore
14. TIG Tungeston Inert Gas
15. WI Work Instruction
16. M.S. Mild steel
17. C.I. Cast Iron
18. FIFO First in First out
19. ISO International Organization for
Standardisation
20. BS British Standard
21. ASTM American Society for testing & Materials
22. SAE Society of automotive engineers
23. AISI American iron and steel institute
24. UTS Ultimate tensile strength
25. DP Die penetrant
26. HYD Hydraulic
27. PRESS Pressure
28. DN Nominal diameter

21-03-2006
REFER STD: ISO10380:2003 Type 1, 2, 3, Claues 6.2

WORK INSTRUCTIONS WI: QA:01
PAGE I OF 2
TITLE: PLIABLE TEST REV. NO. 00 DATE-
PURPOSE: To conduct pliable test on the flexible hose assemblies
TEST EQUIPMENT:
Pliable test rig consisting of 2 nos. wooden cylindrical formers having a radius calculated from
the bend radius (pliable test) as given in the table, test sample of hose assembly of suitable
length, clamps as per hose size.
TEST PROCEDURE :
2 Samples of each nominal size of hose assembly shall be subjected to a bend test. With one
hose end rigidly fixed the other shall be moved in a circular arc around a former having a
radius calculated from the bend radius (pliable test) as given in the table, until the hose
assembly is in intirnate contact with the full length of the arc of the former.
One cycle comprises one bend and return movement to the straight position. The test shall
consist of the assembly being flexed through the no. of cycles which exceeds 10 cycles when
tested at the specified bend radius for Type 1, 2, 3.
After the test, the assembly shall be subjected to the leakage test. There shall be no visible
leakage or any other mode of failure.

21-03-2006
PAGE 2 OF 2
TITLE: PLISBLE TEST REV. NO. 00 DATE-
The rate of flexing shall be from 5 cycle / min to 25 cycle /min
BEND RADIUS AND FORMER DIA AS PER ISO 10380:2003
DN PLIABLE TEST BEND RADIUS AND FORMER DIA IN MM

Type-1,2 Former dia Type-3 Former dia
6 25 20 12 7
8 32 26 16 10
10 38 30 20 12
12 45 35 25 15
15 58 46 25 13
20 70 56 30 16
25 85 66 45 26
32 105 83 60 38
40 130 103 80 53
50 160 126 100 66
65 200 159 115 74
80 240 192 130 82
100 290 230 160 100
125 350 276 -- --
150 400 311 -- --
200 520 405 -- --
250 620 478 -- --

21-03-2006
CYCLIC TEST PAGE 2 OF 6
TITLE: U- BEND TEST REV. NO. 00 DATE-
PROCEURE:
 Make 3 samples per DN size as per the lengths given in the table.
 Test the samples hydraulically at a pressure of 1.5 times the maximum allowable
pressure.
 Mount the hose assembly in the test rig in such a way that distance between the two
arms(ends) will be twice the bend radius (cycle test) given in the table and a vertical
closed loop is formed
 Pressurise the hose assembly to a pressure equal to the maximum allowable pressure.
 Set the stroke length as specified in the table
 Set the counter to zero position.
 Switch on the motor of the test rig and adjust the speed in such a way that flexing
occurs at the of 5 cycles per minute to 30 cycles per minute.
 The hose movement will be 2x where x is equal to 4 DN or 125 mm whichever is

grater.
Note: the hose assemblies shall have and average life of 10,000 cycles but not less than
8000 cycles when tested at the specified bend radius and the stroke length

21-03-2006
TITLE: : U- BEND TEST REV. NO. 00 DATE-
SPECIFIED BEND RADIUS AS PER ISO 10380:2003
DN Cycle Test
Bend Radius ( r) in mm
Type-1 Length Type-2 Length stroke
6 110 565 140 685 125
8 130 645 165 785 125
10 150 725 190 885 125
12 165 785 210 965 125
15 195 905 250 1125 125
20 225 1025 285 1265 125
25 260 1165 325 1425 125
32 300 1328 380 1648 125
40 340 1520 430 1880 160
50 390 1760 490 2160 200
65 460 2100 580 2580 260
80 660 2960 800 3520 320
100 750 3400 1000 4400 400

21-03-2006
TITLE: : CANTILEVER BEND TEST REV. NO. DATE-
PURPOSE:
To Contact cyclic test (Cantilever Bend Test) for Type 1 and Type 2 flexible hose assemblies
from sizes DN 125 to DN 300.
TEST EQUIPMENT
1. Cantilever bend test rig.
2. hyd. Pressure pump with calibrated pressure gauge
3. Electronic digital counter
4. Test samples
GENERAL GUIDELINES:
1. For a given range of corrugated hose assemblies a minimum of 25 samples but not less
than 3 nos. per DN size shall be subjected to the Cantilever Bend Test. If a DN size
fails the test requirement, five further samples of the same DN size shall be tested
without failure.
2. The test shall be conducted with the hose at the relevant maximum allowable pressure.
3. No lubricant shall be added before or during the test..
4. A hose assembly is said to be failed if
(a) Leakage of the hose and/ or

(b) Localized reduction of the hose radius of more than 50 % during the test.

21-03-2006
TITLE: : CANTILEVER BEND TEST REV. NO.00 DATE-
PROCEDURE:
 Make 3 samples per DN size with the flexible length (I) equal to six times the nominal
size.
 Test the samples hydraulically at a pressure of 1.5 times the maximum allowable
pressure as per WI:QA:06
 Mount the hose assembly in the Cantilever bend test rig in such a way that one end is
fix and the other shall be moved by means of a lateral force applied so that a stroke in
the table given will be achieved.
 The hose shall be subjected to a repeated flexing at a sinusoidal rate of from 3

cycles/min. to 15 cycles/ min. in a lateral direction to the axis of the hose.
For Type 1, 2 hoses:
The hose assemblies shall have an average life of 10,000 cycles but not less than 8000
cycles when tested at the specified stroke length.

21-03-2006
TITLE: : CANTILEVER BEND TEST REV. NO.00 DATE:
SPECIFIED STROKE AS PER ISO 10380:2003
Nominal Size Flexibility Length

DN Type -1 stroke Type-2 Stroke
125 65 50 750
150 70 55 900
200 80 65 1200
250 90 70 1500
300 100 80 1800

21-03-2006
PAGE 1 OF 1
TITLE: : YIELD AND BURST PRESUURE REV. NO.00 DATE:
TEST
REF. STANDARD: ISO 10380-2003 CLAUSE 6.4.2, 6.4.3, 5.3.1.3, 5.3.1.4
TEST EQUIPMENT:
1. Hydraulic Pressure Test pump fitted with calibrated pressure gauge of suitable range.
2. A enclosure for covering over the sample.
3. Steel scale 1 meter long.
4. Test sample of minimum 500mm length between Ferrules. One end closed, other end
fitted with suitable end fitting to accommodate the end fitting of test pump.
TEST PROCEDURE:
1. Make the sample of hose assay of approx 500 mm or 5 times greater of the nominal
bore whichever is greater with one end closed and other having fitting matching with
fitting of test pump.
2. Pressurise the sample to check that the end fittings do not leak. Tighten the end
connection if required to ensure that there is no leakage.
3. Note down the initial length of the hose assembly test sample between Ferrules.
4. Now gradually increase the pressure of 1.5 times the maximum allowable pressure.
5. Now release the entire pressure and measure the length.
6. The permanent elongation shall not be more than 1% of test length.
7. Now increase the pressure gradually in steps as per the least count of the pressure
gauge.
8. Increase the pressure further step by step until the hose assembly sample fails.
 Failure is considered if there is any visible leakages or rupture of any
components.
 In case the sample assembly fails at a pressure less than 4 times the design
pressure, the sample may be treated as failed.
Note:- The burst pressure of the hose assay shall not be less than 4 times of the maximum
allowable pressure.

21-03-2006
REF. STANDARD: ISO 10380-2003 Clause 7.3

PRESSURE PROOF TEST PAGE 1 OF 2
TITLE: : LEAK TEST REV. NO.00 DATE:
SCOPE: All the hose assemblies and hoses
TEST EQUIPMENT:
1. Air Compressor of suitable pressure capacity
2. Suitable fixture for testing hoses/ assemblies
3. Calibrated pressure gauge of suitable range and least count
4. Water tank of suitable size to accommodate the hose assembly/ hoses.
NOTE:
 Unbraided hose/assemblies upto DN 100 shall be tested at a pressure of 1-

1.5kg/cm2, size above DN 100 should be tested at 0.5 – 1.0 kg/cm2 to avoid
elongation.
 Hose assemblies with pressure ratings upto and including 20 bar shall be tested at
10% of the rated pressure hose assemblies rated above 20 bar shall be tested at 2
bar.
 The hose assemblies may be tested upto 10 bar as per the instructions for specific
orders.
 The holding time should be minimum 2 min.

21-03-2006
TITLE: : LEAK TEST REV. NO.00 DATE:
TEST PROCEDURE:
1. Close both the ends of the hose assembly with suitable end fittings.
2. Put the hose assembly in the water tank.
3. Pressuries the hose assembly/ hose by air
4. Give the pressure as specified and maintain the specified holding time 2
minutes.
5. Monitor the sample for bubbles.
6. Leakage if any can be detected when the bubbles comes out.
7. If no bubbles appear on the surface of water, the hose/hose assembly is said to

have passed the leak test.
8. In case leakage is observed identify with red colour/ or white strip.
9. After rectification again test. If OK then send for further processing.

21-03-2006
TITLE: : HYDRAULIC TEST REV. NO.00 DATE:
SCOPE: For all type of hose assemblies (Type 1,2,3)
REFERENCE STANDARD.: ISO 10380:2003 Clause 7.2.2.
TEST EQUIPMENT:
A) Hydraulic Test Pump
B) Water having chloride Ontent less than 30 mg/I (DM water).
C) Calibrated Pressure Gauge.
PROCEDURE:
1. Close one end of the hose assembly by suitable stopper or blind flange.
2 .fill the hose assembly with DM water from other end.
3 Fix suitable end fitting on the other end to accommodate the hose of the test pump.
4 Pressure the hose assembly by test pump and remove air trapped inside trough a
breather valve.
5 Keep on pressurizing the hose assembly till the pressure gauge indicates pressure equal
15 times the maximum allowable pressure i.e. the test pressure.

21-03-2006
TITLE: : HYDRAULIC TEST REV. NO.00 DATE:
6. The test pressure shall be applied and maintained for a sufficient length of time to
permit a visual examination of all surface points (2-3 minutes) /minute for hoses upto
DN 50, 2 minutes for hoses 50<DN 100 and 3 minute for hoses DN>100.
7. Check the hose assembly welded joints visually and by hand to check any
leakage/swetting of welded points.
8. Also check the entire length by hand for any kind of leakage, droplets of water,
swetting etc.
9. In case no leakage is observed the hose assembly is said to have passed the hydraulic
test.
10. In case there is any leakage, mark the point of leakage.
11. The leak hose assembly shall be marked with red colour code/ white plastic strip and
then sent for recitification.
12. Rectified assembly is again tested as above and released if found OK in hydraulic
testing.

21-03-2006
PAGE 1 OF 1
TITLE: : ERICHSEN CUPPING TEST REV. NO.00 DATE:
PURPOSE: To conduct Erichsen deep drawing test during the operation of tube welding to
access the quality of welding seam.
Reference standard : ISO10175 (part-1):1993

ISO8490: 1986
TEST PROCEDURE:
1) Cut the piece of tube and flatten it (to access the quality of weld sheet). The test
piece should have a width of 70mmminimum and grease should be applied on
the specimen.
2) Insert the specimen in the tester and locate it by means of test piece holder.
3) Clamp the specimen against the face of furrow holder by advancing the back
screw. Now set any one of the zero on the back dial with zero line on the main
body. Now rotate the back screw in the opposite direction. (ie in declamping
direction ) by five divisions on back dial.
4) Bring the punch in contact with the specimen in such a manner so as to avoid
any sudden impact, continue rotating the hand wheel slowly and uniformly
thereby the specimen is uniformly cupped by causing the punch to advance.
5) Erichsen number indicates the distance in millimeters of the travel of punch top
from specimen holding surface upto the points where the first crack is made on
the reverse side of the specimen.
6) Now record the erichsen value indicated on the scale and front dial.
7) The erichsen value in mm should not be less than d/2,20/2=10 mm where

d=diameter of punch in mm

21-03-2006
PAGE 1 OF 1
TITLE: LIQUID PENETRANT REV. NO.00 DATE:
EXAMINATION (DP TEST)
Scope: To conduct Dye penetrant test on the welded joints of hose assemblies if required
by the customer.
Test equipment: The following chemical spray cans are required:
1-CLEANER CL-96
2-PENETRANT-PT-97
3-DEVELOPER DV-98
4-HOSE ASSEMBLY TO BE TESTED
TEST PROCEDURE:
PRECLEANING- The welded surface should be cleaned thoroughly with the help of CL-
96 ensuring the freedom from grease and paint etc and let it dry for 2-3 minutes.
PENETRANT APPLICATION- Apply dye penetrate PT-97 and leave it as it is for

dwelling period of 15-20 minutes.
PENETRANT REMOVAL-Remove the dye penetrate carefully with the remover CL-96
with a cloth softly and ensure the dry surface.
DEVELOPING- Shake the can DV-98 vigorously and apply the developer uniformly over
the surface.
INSPECTION- No bright red indications should be visible.

21-03-2006
WORK INSTRUCTIONS WI: RM:01
PAGE 1 OF 1
TITLE: S.S COIL SPECIFICATION REV. NO.00 DATE:
Material: Colled rolled coils of deep drawing quality.

Reference specifications : ASTM:A240, EN 10028-7
Chemical composition:
Type Chemical composition (%)

ASTM
C S Mn Si P Cr Ni Mo Ti Any
max. max. max. max max other
304 0.08 0.03 2.00 0.75 0.045 18.00- 8.00- -- -- N-0.1
20.00 10.50 max
304L 0.03 --do-- --do-- --do-- --do-- 18.00- 8.00- -- -- N-0.1
20.00 12.00 max
316 0.08 --do-- --do-- --do-- --do-- 16.00- 10.00- 2.00- -- N-0.1
18.00 14.00 3.00 max
316L 0.03 --do-- --do-- --do-- --do-- 16.00- 10.00- 2.00- -- N-0.1
18.00 14.00 3.00 max
316 Ti 0.08 --do-- --do-- --do-- --do-- 16.00- 10.00- 2.00- 5(C+N) N-0.1
18.00 14.00 3.00 max. max
0.70
321 0.08 --do-- --do-- --do-- --do-- 17.00- 9.00- -- 5(C+N) N-0.1
19.00 12.00 max. max
0.70
Type ASTM Mechanical Properties

UTS (N/MM2) YS(N/mm2) min. % Elongation, Hardness RB
min. min. max.
304 515 205 40 92
304L 485 170 --do-- 92
316 515 205 --do-- 95
316L 485 170 --do-- 95
316Ti 515 205 --do-- 95
321 515 205 --do-- 95
1N/mm2=1 Mpa
Finish: No surface imperfection are accepted.
Finish may be dull or bright.

21-03-2006
PAGE 1 OF 1
TITLE: S.S STRIP SPECIFICATION REV. NO.00 DATE:
The standard specification of SS Strips is as under
1 /4 0.20 33 +0.10 0.02 For mech. Corr.

3/8 0.20 49 --do-- --do-- --do--
1 /2 0.00 55.5 --do-- --do-- --do--
1/ 2 0.22 41 --do-- --do-- For Hyd. Corr.
5/ 8 0.20 63 --do-- --do-- --do--
3 /4 0.22 81 +0.10 0.02 --do--
3/ 4 0.22 64 +0.10 0.02 For Hyd. Corr
1 0.30/0.25 81 --do-- --do-- For Hyd. Corr
1-1/4 0.30 103 --do-- --do-- --do--
1 -1/2 0.30 128 --do-- --do-- --do--
2 0.30 160 --do-- --do-- --do--
2-1/2 0.30 207 +0.20 0.05 --do--
3 0.3/0.35/0.40 253 --do-- --do-- --do--
4 0.3/0.35/0.40 318 --do-- --do-- --do--
5 0.4/0.50 395 --do-- --do-- --do--
6 0.4/0.50 475 --do-- --do-- --do--
8 0.50 620 --do-- --do-- --do--
10 0.63 780 --do-- --do-- --do--
Director Can Permit devastations in above specifications.

21-03-2006
PAGE 1 OF 1
TITLE: S.S HOSE SPECIFICATION REV. NO.00 DATE:
SCOPE: Specifications of stainless steel corrugated hose with one or two braiding.
SPECIFICATIONS:
1. Nominal dia of hose (ID) in mm.

2. Thickness of strip in mm.
3. Outer diameter of Hose O.D without braiding.
4. No. of corrugations per meter.
5. Pitch of corrugations 1000 divided by no. of corrugations.
6. Weight of the unbraided hose in kg per meter.
7. Thickness of the strip used.
8. Outside diameter with one braid.
9. Weight of hose with one braid in kg per meter.
10. Outside diameter with two braids.
11. Weight of the hose with two braids.
12. Nominal bore (NB) in mm.
13. Maximum recommended working pressure of hose without braid (unbraided hose).
14. Maximum recommended working pressure of hose with one braid.
15. Recommended test pressure with one braid
16. Burst pressure with one braid.
17. Maximum recommended working pressure with two braids.
18. Test pressure with two braids
19. Burst pressure with two braids.
20. Bend radius.
For details refer product catalogue

21-03-2006
PAGE 1 OF 1
TITLE: S.S WIRE SPECIFICATION REV. NO.00 DATE:
MATERIAL: Austenitic stainless steel
REFERENCE STANDARD: BS 1554
Type C% Si% Mn% S% P% Cr% Ni% Mo% Ti% Max
Max Max Max Max Max
304S31 0.07 1.0 2.0 0.030 0.045 17-19 8-11 -- --
321S31 0.08 1.0 2.0 0.030 0.045 17-19 9-12 -- 5XC min,
0.8 max
316S19 0.07 1.0 2.0 0.030 0.045 16- 10-14 2-3 --
18.5
MECHANICAL PROPERTIES
TYPE WIRE DIAMETER(MM) UTS(N/MM2) TOLERANCE ON DIA

304S31 0.30,0.37 700-900 +0.0085
0.50,0.60,70 620-820 +0.010
316S19 0.30,0.37 700-900 +0.0085
0.50,0.60,0.70 620-820 +0.010
321S31 0.30,0.37 700-900 +0.0085
0.50,0.60,0.70 620-820 +0.010
NOTE: THE CARBON CONTENT SHOULD NOT BE MORE THAN 0.045%
 SS WIRE SHOULD BE CHECKED VISUALLY FOR THE FOLLOWING
 CONDITION OF WIRE WINDING IN THE SPOOLS
 SURFACE FINISH OF THE WIRE

21-03-2006
PAGE 1 Off 2
TITLE: PACKING INSTRUCTIONS REV. NO.01 DATE:10-8-2010
SCOPE: All Type of finish material (Hose / Braiding/ Fittings/Hose Assemblies/Automotive

exhaust connectors)
TYPE OF PACKING IS DIVIDED INTO 3 MAIN CATEGORIES

1. Seaworthy Packing
2. Airworthy packing
3. Road worthy/rail worthy packing
SEA WORTHY PACKING:
A-Full container load

B-Less than container load
A. When the material is to be dispatched in full container each hose length from 3” to 8”
nb is to be wrapped in bubble sheets length wise and adhesive tape is wrapped. Hose
lengths from ¼” to 2”nb are to be made in the form of bundles ie coils and then
wrapped in the bubble sheets. In case of customer requirements the ¼ to 2” hoses can
be packed in wooden reels also.
The standard packing of exhaust connectors is 25 pieces in each corrugated box. The
individual pieces are separated by sections made in the carton boxes inorder to avoid
rubbing and damages during transit. These corrugated box. are to be dispatched in the
container as it is or needs to be packed in wooden boxes before placing in the container
is at the discretion of the customer. As per the customer requirements the material is
dispatched.
B. When the material is to be dispatched in less than container load it has to be packed in
plywood boxes. The size of boxes is not constant and depends on the size and quantity
of the hoses. Care should be taken while fixing the nails in the boxes so that the
material inside the boxes do not get damaged. All the wooden boxes should have 3”x3”
wooden planks fixed on the bottom of boxes to facilitate handling by fork lifter. All
sides of the boxes to be provided with metallic strips to avoid damage/opening of
boxes.
The standard packing of exhaust connectors is 25 pieces in each corrugated box. The
individual pieces are separated by sections made in the carton boxes inorder to avoid
rubbing and damages during transit. These corrugated box. are to be dispatched in
wooden boxes or as per the customer requirements.

21-03-2006
PAGE 2 Off 2
TITLE: PACKING INSTRUCTIONS REV. NO.01 DATE:10-8-2010
MARKING AND LABELLING:
The corrugated /Plywood boxes are marked with the contents inside each box and the list
is displayed on the boxes with marking of size, quantity, length , item code or the marking
as per the customer requirements.
AIRWORTHY PACKING:
All material is to be packed in suitable corrugated boxes. For auto exhaust connectors the
material is packed standard packing of 25 Pieces in each corrugated box is proper adhesive
tape is to be affixed at all box openings.
All boxes to be wrapped by white markin cloth and stitched if required. Plastic strap should
be tightened from four sides by strapping machine. Standard Labelling and marking is done
as specified above in case there is no specific customer requirement.
ROAD /RAIL WORTY PACKING:
All material being dispatched by road/rail for Indian market can be packed in:
1. Wooden boxes
2. Corrugated boxes
3. Gunny bundles
Or as per any specific customer requirement
Care should be taken for proper identity by putting customer name/destination on all
packets.
Hoses/assemblies to be wrapped in bubble sheets before packing. Ms trips to be used for

packing with strapping machine.
Wooden boxes to be used for flanged assemblies up to length 24 inches.
Corrugated boxes to be used for packing bare hoses and braiding. Gunny bundles to be
used for all other hose assemblies as suitable
During rainy season of the year from month of June to august. All the corrugated boxes to
be wrapped additionally by polythene sheets all around to protect them from rain.
All the corrugated boxes to be reinforced by wrapping and sticking jute cloth all around

21-03-2006
PAGE 1 OF 1
TITLE: SPECIFICATION OF WELDING REV. NO.00 DATE:
FILLER RODS
Reference standard: BS2901-PART-II-1990
Chemical composition (% by mass) of filler rods is as below:
TYPE C Si Si Mn Mn P S Cr Cr Mo Mo Ni Ni
max min max min max max max max max min max min max
309S94 0.04 0.25 0.65 1.0 2.50 0.03 0.03 23.0 25.0 -- 0.50 12.0 14.0
to0.12
316S92 0.03 0.25 0.65 1. 2.50 0.03 0.03 18.0 20.0 2.0 3.0 11.0 14.0
 The length and the diameter of the filler rods shall be as per requirement

21-03-2006
WORK INSTRUCTIONS WI: GEN:01
PAGE 1 OF 2
TITLE: SAMPLING PLAN REV. NO.01 DATE:15.05.10
Raw Material:
 SS Coil –No testing if TC. is available/received, if TC not recd. Sample is taken from
every coil to do following test
 Chemical analysis
 Physical-Hardness, T.S & elongation. Check testing to be done as per
plan
 Width & thickness of coil to be verified.
 For other incoming materials (SS wire, SS/GI Coil, Cap, End fittings etc) sampling plan
is followed as
Lot size Nos Sample size Nos

1-10 3
11-25 5
26-100 10
Above 100 12
Radioactive testing
 Radioactive testing to be done from every lot of End –Fittings, coils & wire with the help of
red check meter type: RC 705 B.
 After Slitting of coil inspection is done 100% for the following:

 Width
 Visual –To see packing (loose or tight), burrs, tags.
 Thickness.
 Tube Forming:
 At the start of process one sample is taken for coupling test from the size
produced for setup approval and cupping test is carried out every 2 hrs.
 Hose joining:
During Hose joining process inner hose joining section will be monitored with rigid camera for
above parameters.
1. Corrugation cut edges ---- No burr allowed on cut edges.

2. Welding Colour ----- Should be yellow Or White. (Welding colour black & blue is not
acceptable).
3. Joints will be monitored on Daily basis & record will be maintained.
 Hose forming:
 Hose OD –every length. Three readings (average)
 Corrugation / mt-Two readings (average) every length.
 Type test—for any size produced, once in a year.
 In case (reqd. by customer) this testing is to be done for every size.

21-03-2006
PAGE 2 OF 2
TITLE: SAMPLING PLAN REV. NO.01 DATE:15.05.10
 Assembly:
 Welding seam to be compared with the reference sample.
 Conduct D.P test of atleast one welded assembly in a day.(no defect
should be there )
Final inspection
 100% inspection is done to verify overall length, grade and pneumatic pressure testing.
 From every lot of assembly dimensions of end –fittings and hydraulic pressure testing
is to be done as follows:
Lot Size Sample Size

1-10 1
11-25 3
26-100 08
above 100 10
All Pcs (sample) should conform to specifications.
Helium leak testing
 Helium leak testing will be done on all critical application hose assemblies, lance hoses.
Record will be maintained.
.

21-03-2006
PAGE 1 OF 1
TITLE: Corrugating machine operating REV. NO.00 DATE:
parameters
Water pressure to be set on the corrugation forming machine is as given below:
Nominal size of the hose(mm) Water pressure (kg/cm2)

20 100-125
25 100-125
32 90-100
40 80-90
50 70-80
65 60-70
80 50-60
100 40-50
125 40-50
150 40-50
200 50-60
250 5060
 Dm water should be used having the chloride content less than 30 mg/l.
 2% cutting oil should be changed as required.
 Machine parameters should be set as specified.
 Try small piece and inspect it as per specifications
 Reset the machine if required.
 Check the seal after every length of hose is made and replace if necessary.

21-03-2006
PAGE 1 OF 1
TITLE: TUBE WELDING REV. NO.01 DATE:1-
1-2007
Process: Gas Tungsten re welding (GTAW)
Type: Semi automatic
Gas Shielding- Argon flow rate as per WPS/PQR

15-25 LPM
Purging-Argon
Electrical characteristic:
Thickness (mm) Current in amperes

Up to 0.25 20-35
0.25-0.30 35-45
0.40-0.63 45-60
Polarity: Base Metal (+ve)

TIG Torch (-ve)
Electrode: 2% Throted Tungsten, Ø 2.4 mm
Travel speed: 1.5 m/min
General:
 Set machine as per specified parameters above and see WPS/PQR

 Change forming dies and rubber pads as per size.
 Align the centerline of the rubber pads with respect to the tube.
 Use protective glass to observe the Welding Arc, Shield the arc by glass wool.
 Use cotton hand gloves while operating the machine.
 Ensure strip is free from oil, grease, etc.
 Colour of Welding bead should be white inside and outside.
 Now do the cupping test as per WI:QA:07 and if found ok then run the machine
 Oxide color acceptance criteria defined in WI:GEN:22

21-03-2006
PAGE 1 OF 1
TITLE: Preventive Maintenance corrugating REV. NO.01 DATE:
machine 1 & 2
DAILY CHECKS: Before start
1. Check level of hydraulic oil in the reservoir. Top up if necessary.

2. Clean the machine head and other parts by waste cotton for dust,water drops etc.
3. Check the leaking connections of hose and other pressure pipes and set them right.
4. Check water level in water tank and top up if necessary.
5. Check the condition of forming dies and replace if necessary.
6. Apply grease/oil on LM guides, Tie rods.
7. Switch on the motor and check movements of all cylinders & moving plates.
Checks –After the production is stopped.
1. Clean/wipe off water from the machine head, L.M. guides, tie rods and other
moving/stationary parts to avoid rusting.
2. Cover the machine by closing all the shutters of the machine cover.
3. Cover the PLC control panel.
4. Switch off power supply to the machine from main switch.

21-03-2006
PAGE 1 OF 1
TITLE: Preventive Maintenance –Tube REV. NO.01 DATE:
forming & welding machine
DAILY CHECKS BEFORE STARTING PRODUCTION
1. Clean the machine head, forming moulds & welding head and remove dust, oil or
grease from the forming and welding stations.
2. Apply grease on chain and sprocket drive , worm drive, splines shaft drive if required.
3. Check level /pressure of Argon gas.
4. Check top of the electrode before starting the production.
CHECKS AFTER THE PRODUCTION IS STOPPED
 Switch off the power supply to the machine from the main switch.

21-03-2006
PAGE 1 OF 1
TITLE: Assembly machine REV. NO.01 DATE:
Scope: Unless and other wise specified by a customer, following method for assembly will
be followed.
Process: TIG welding with argon gas shielding. The welding parameters shall be as per
approved WPS & PQR.
Method of welding:
Preparation: The hose shall be cut in the groove at the nearest point of corrugation. The
projected sharp edges will be dressed. A neck ring will then be inserted on the hose and
braiding in such a way that the braiding wires protrude little over hose and ferrule (by 1-3
mm)
Welding stage1 : The welding of hose, braiding and neck ring(ferrule) will be done in such
a way that braiding wires get fused/bonded securely in the joint with hose and neck ring.
Generally no filler wire will be used in stage 1.
Welding stage 2: the end fitting shall then be welded to the hose and neck ring by second
weld. Suitable size of filler wire be used for doing second weld.
Material Filler rod to be used

Carbon steel & stainless Steel ER 309L
Stainless steel & Stainless Steel ER 316 L
Diameter of hose Filler rod dia

First weld for all sizes 1.6 mm
Subsequent welding layers 2.0/2.5 mm
All the other welding parameters should be as per approved WPS/PQR General:
 Use protective glass shield to observe welding Arc.

 Ensure material is free from oil, grease etc.
 Monitor the welding bead as per reference sample provided.

21-03-2006
PAGE 1 OF 1
TITLE: ERICHSEN CUPPING TEST REV. NO.00 DATE:
PURPOSE: To conduct Erichsen deep drawing test during the operation of tube welding to
access the guality of welding seam.
Reference standard: ISO10175(PART-1):1993

ISO 8490:1986
Test equipment: Erichsen cupping tester and the test samples.
TEST PROCEDURE:
1) Cut the piece of tube and flatten it (to access the quality of weld sheet). The test
piece should have a width of 70mm minimum and grease should be applied on
the specimen.
2) Insert the specimen in the tester and locate it by means of test piece holder.
3) Clamp the specimen against the face of furrow holder by advancing the back
screw. Now set any one of the zero on the back dial with zero line on the main
body. Now rotate the back screw in the opposite direction (ie in declamping
direction) by five divisions on back dial.
4) Bring the punch in contact with the specimen in such a manner so as to avoid
any sudden impact, continue rotating the hand wheel slowly and uniformly
thereby the specimen is uniformly cupped by causing the punch to advance.
5) Erichsen number indicates the distance in millimeters of the travel of punch top
from specimen holding surface upto the points where the first crack is made on
the reverse side of the specimen.
6) Now record the erichsen value indicated on the scale and front dial.
7) The erichsen value in mm should not be less than d/2,20/2=10mm where

d=diameter of punch in mm
8)
21-03-2006
PAGE 1 OF 1
TITLE: HOSE TO HOSE WELDING REV. NO.00 DATE:
Scope: corrugated hoses will be jointed by following two TIG welding method. (Unless
and other wise required by the customer Edge welding is to be followed.)
Method: following methods will join Corrugated hoses by TIG welding.
1. Butt Welding: In this method one full corrugation of one hose length will be welded
with one full corrugation of the other hose by making butt joint as shown in fig. below
by TIG welding.
The hose shall be tested after butt welding by pneumatic pressure test procedure to
Ensure a leak proof joint..
Preparation of edges: The hose end should be cut perpendicularly to hose axis at nearest
point of corrugation in the groove. The burrs on the cut edge should be dresses or removed
by suitable means before welding. Ensure that end corrugation is cleaned to remove any
trace of oil before starting of welding operation.
2. Edge Welding: In this method one corrugation at the end of two hoses to be joined is
compressed in such way that the thickness of the compressed corrugation reduces to
about half. Then the compressed corrugation of two hoses are welded butting them
together as shown in figure below:
The above joining of hoses may do the fusion welding also
General:
 Use protective glass shield to observe welding Arc.
 Ensure material is free from oil, grease, e.t.c.
 Monitor the welding bead as per reference sample provided.

21-03-2006
PAGE 1 OF 2
TITLE: Specifications for bobbin winding REV. NO.00 DATE:1-1-
2007
APPLICABLE FOR 72 CARRIERS BRAIDING MACHINE ONLY
SNO SIZE WIRE DIAMETER NO OF WIRES

STANDARD HEAVY STANDARD HEAVY
SERIES SERIES SERIES SERIES
1) 3” 0.45 0.50 09 08
2) 4” 0.45 0.50 11 10
3) 5” 0.63 0.70 09 09
4) 6” 0.63 0.70 10 10/11
5) 8” 0.63 0.70 14 13
6) 10” 0.70 0.70 14 14

21-03-2006
PAGE 2 OF 2
TITLE: Specifications for bobbin winding REV. NO.00 DATE:1-1-
2007
FOR 48 CARRIERS BRAIDING MACHINE ONLY
SNO SIZE WIRE DIAMETER NO OF WIRES

STANDARD HEAVY STANDARD HEAVY
SERIES SERIES SERIES SERIES
1) 1/4” 0.30 0.30 03 03
2) 3/8” 0.30 0.30 04 04
3) ½” 0.30 0.30 05 05
4) 5/8” 0.30 0.30 06 06
5) ¾” 0.30 0.30 07 07
6) 1” 0.28 0.30 10 09
7) 1-1/4” 0.37 0.37 07 07
8) 1-1/2” 0.37 0.37 09 09
9) 2” 0.50 0.50 08 08
10) 2-1/2” 0.45 0.50 12 10
FOR 24CARRIERS BRAIDING MACHINE ONLY
S NO SIZE WIRE DIAMETER NO OF WIRES

1. ¼” (BI) 0.30 05
2. ¼”(RF) 0.30 06
3. 3/8” 0.30 08
4. ½” 0.30 10

21-03-2006
PAGE 1 OF 2
TITLE: Specifications of corrugated hoses REV. NO.01DATE:10-
(standard series hoses) 12-2006
S .No. Size of Hose Hose OD No of

Corrugations
NB (inches) ID(mm) Thickness Mm Per mtrs
(mm)
1. ¼(c-6) 6.5 + 0.2 0.20 11.0+0.2 450+20
2. 5/16” 7.9 + 0.5 0.20 12.2+0.5 420+20
3. 3/8(c-6) 10 +0.2 0.20 146+0.2 330+20
4. ½(c-6) 13 + 0.2 0.20 18.2+0.2 300+15
5. ½(c-3) 13.5 + 0.5 0.20 19.2+0.2 280+10
6. 5/8 16+0.5 0.20 22.5+0.5 275+10
7. ¾ (c-3) 20+0.5 0.20 27+0.5 265+10
8. 3/4(c-5) 20+0.5 0.25 27+0.5 210+10
9. 1 25.50 0.26 34.5+0.5 210+5
10. 1-1/4 32.50 0.26 41.0+0.4 205+5
11. 1-1/2 40.70 0.26 50.50+0.4 185+5
12. 2 50.60 0.30 63.50+0.4 135+5
13. 2-1/2 65.60 0.30 78.50+0.4 135+5
14. 3 50.20 0.30 95+0.4 105+5
15. 4 100.60 0.31 116+0.4 95+5
16. 5 125 0.35 143+0.5 90+5
17. 6 148 0.40 172+0.5 75+5
18. 8 198 0.50 225+0.5 70+5
19. 10 248 0.60 281+1 65+3
 There should be no dia marks on the hose.

 There should be no uneven gaps between the corrugations.
 The OD of hose should be uniform
 OD of 8” hose to be checked by snap gauge.

21-03-2006
PAGE 2 OF 2
TITLE: Specifications of Width and REV. NO.01DATE:10-
thickness (for Heavy series Hoses) 12-2006
S .No. Nominal Size of Hose Hose OD No of

Corrugations
NB (inches) ID(mm) Thickness mm Per mtrs
(mm)
1. ¼(c-6) 6.5 + 0.2 0.20 11.0+0.2 450+20
2. 5/16” 7.9 + 0.5 0.20 12.2+0.5 420+20
3. 3/8(c-6) 10 +0.2 0.20 146+0.2 330+20
4. ½(c-6) 13 + 0.2 0.20 18.2+0.2 300+15
5. ½(c-3) 13.5 + 0.5 0.22 19.2+0.2 280+10
6. 5/8 16+0.5 0.22 22.5+0.5 275+10
7. ¾ (c-3) 20+0.5 0.22 27+0.5 265+10
8. 3/4(c-5) 20+0.5 0.25 27+0.5 210+10
9. 1 25.50 0.26 34.4+0.5 210+10
10. 1-1/4 32.50 0.30 42+0.5 190+10
11. 1-1/2 40.70 0.30 52+0.5 150+10
12. 2 50.60 0.30 65+0.5 130+5
13. 2-1/2 65.60 0.30 81+0.5 120+5
14. 3 50.20 0.30 95+0.5 110+5
15. 4 100.60 0.35 117+0.5 100+5
16. 5 125 0.40 145+0.5 90+3
17. 6 150 0.40 175+0.5 80+3
18. 8 198 0.50 228+0.5 75+3
19. 10 248 0.60 281+1 65+3
 There should be no dia marks on the hose.

 There should be no uneven gaps between the corrugations.
 The OD of hose should be uniform
 OD of 8”,10” hose to be checked by snap gauge.

21-03-2006
PAGE 1 OF 2
TITLE: Specifications of strip Width and REV. NO.01DATE:10-
thickness (for Standard series Hoses) 12-2006
S. NO. Size of Hose Strip width (mm) Strip thickness

(inches) (mm)
1. ¼ 30+ 0.1 0.20
2. 3/8 41+ 0.1 0.20
3. ½ (c-3) 55.5+0.1 0.22
4. ½ (c-6) 52.5+0.1 0.20
5. 5/8 64+0.1 0.22
6. ¾(c-3) 81+0.1 0.22
7. ¾(c-5) 81+0.1 0.25
8. 1 81+0.1 0.26
9. 1-1/4 103+0.1 0.26
10. 1-1/2 128+0.1 0.26
11. 2 160+0.1 0.30
12. 2-1/2 207+0.2 0.30
13. 3 253+0.2 0.30
14. 4 318+0.2 0.31
15. 5 395+0.2 0.35
16. 6 466+0.2 0.40
17. 8 620+0.2 0.50
18 10 780+0.2 0.60
19. 5/16” 35+0.1 0.20
Tolerance on strip thickness is + 0.020 mm
Strip to be visually inspected for the following:

 Quality of packing
 Uniform burrs across width
 Tags/identification of coils
Note: Hoses from size ¼” NB to ¾”NB are with same specifications in standard and
heavy series

21-03-2006
PAGE 2 OF 2
TITLE: Specifications of strip Width and REV. NO.01 DATE:10-
thickness (for Heavy series Hoses) 12-2006

(inches) (mm)
1. ¼ 30 ± 0.1 0.20
2. 3/8 41 ± 0.1 0.20
3. ½ (c-3) 55.5 ± 0.1 0.22
4. ½ (c-6) 52.5 ± 0.1 0.20
5. 5/8 64 ± 0.1 0.22
6. ¾(c-3) 81 ± 0.1 0.22
7. ¾(c-5) 64 ± 0.1 0.25
8. 1 81 ± 0.1 0.26
9. 1-1/4 103 ± 0.1 0.30
10. 1-1/2 128 ± 0.1 0.30
11. 2 160 ± 0.1 0.30
12. 2-1/2 207 ± 0.2 0.30
13. 3 253 ± 0.2 0.30
14. 4 318 ± 0.2 0.35
15. 5 395 ± 0.2 0.40
16. 6 466 ± 0.2 0.40
17. 8 620 ± 0.2 0.50
18 10 780 ± 0.2 0.60
19. 5/16” 35 ± 0.1 0.20
 Burrs across width
 Tags/identification of coils

21-03-2006
PAGE 1 OF 2
TITLE: Specifications of Braiding REV. NO.01DATE:1-1-
2007
For 48 Carriers Braiding Machine
SN Hose Size Wire Diameter No of wires Braid Angle

in inches (mm) (deg)
Heavy Standard Heavy Standard Heavy Standard
series series series series series series
1. ¼” 0.30 0.30 03 03 80 80
2. 3/8” 0.30 0.30 04 04 80 80
3. ½” 0.30 0.30 05 05 80 80
4. 5/8” 0.30 0.30 06 06 80 80
5. ¾” 0.30 0.30 07 07 80 80
6. 1” 0.30 0.28 10 10 85 80
7. 1-1/4 0.37 0.37 07 07 90 90
8. 1-1/2” 0.37 0.37 09 09 96 90
9. 2” 0.50 0.50 08 08 90 90
10. 21/2” 0.50 0.45 10 10 98 95
Sno. Hose size in inches Wire Diameter No of wires

(mm)
1. ¼”(Bl) 0.30 05
2. ¼”(RF) 0.30 06
3. 3/8” 0.30 08
4. ½” 0.30 10

21-03-2006
PAGE 2 OF 2
TITLE: Specifications of Braiding REV. NO.01DATE:1-1-
2007
SN Hose Size Wire Diameter No of wires Braid Angle

in inches (mm) (deg)
Heavy Standard Heavy Standard Heavy Standard
series series series series series series
1. 3” 0.45 0.50 09 08 90 90
2. 4” 0.45 0.50 11 10 90 90
3. 5” 0.63 0.70 09 09 90 90
4. 6” 0.63 0.70 10 10/11 90 90
5. 8” 0.63 0.70 14 13 90 90
6. 10” 0.70 0.70 14 14 100 100

21-03-2006
PAGE 1 OF 1
TITLE: Preventive maintenance of lathe REV. NO.00 DATE:
Specifications of Braiding
Daily checks before start:
1. Clean the machine properly by cotton waste.

2. Oiling on head stop, bed, cross slides, lead screw, feed rod and tail stock.
3. Greasing on gear wheels
4. Check the movement of the carrier and cross slide.
5. Start the machine and check the direction of chuck (rotation0.
Daily checks after the production is stopped
1. Clean the machine by brush.

2. clean all the tools and spanners by cotton waste and keep it in the tray.
3. Switch off the power supply to the machine from the main switch.

21-03-2006
PAGE 1 OF 3
TITLE: Preventive maintenance of 20Kva REV. NO.00 DATE:
power generator
Daily checks before start:
1. Clean the DG set by cotton waste.

2. Fill the water in the radiator top up.
3. Check the level of mobile oil if it is less the mark of top up.
4. Check the charge of battery
5. On the ignition switch
6. Start the DG set
7. Check the pressure of the oil in the pressure gauge (4-6kg/cm2).
8. Check the temperature of water.
9. Check the voltage and current (440 volts).
Note: in case of any problem with regards to the above report to the production manager

21-03-2006
PAGE 2 OF 3
TITLE: Preventive maintenance of 4Kva REV. NO.00 DATE:
power generator
Daily checks before start

2. fill the water in the radiator to up.
3. check the level of mobile oil if it is less the mark of top up.
4. check the charge of battery
5. on the ignition switch and check its working
6. start the DG set

21-03-2006
PAGE 3 OF 3
TITLE: Preventive maintenance of 82.5Kva REV. NO.00 DATE:
power generator

2. fill the water in the radiator top up.
3. check the level of mobile oil if it is less the mark of top up.
4. check the charge of battery
5. on the ignition switch and check its working
6. start the DG set
7. Check the pressure of oil in the pressure gauge (should not be less than 1.75kg/cm2)
8. Check the temperature of water (reading should not cross green mark. If so stop DG set.
9. Check the voltage(415-420).

21-03-2006
PAGE 1 OF 1
TITLE: Preventive maintenance of milling REV. NO.00 DATE:
machine
1. Clean the machine properly by cotton waste.

2. Do the oiling on the machine head, vertical slide and longitudinal slide.
3. Check the x, y, z axis of the DRO.
4. Check the movement of x, y, z axis ways.
After stopping work
1. Clean the machine by brush.

2. Clean all the tools and keep it in the almirah.
3. Switch off the power supply t the machine from the main switch.
Monthly checks
1. Clean the machine properly.

2. Clean the entire axis x, y, z slides, lead screw, vertical screen by oil.
3. Apply grease and oil wherever necessary.

21-03-2006
PAGE 1 OF 1
TITLE: Preventive maintenance of argon arc REV. NO.00 DATE:
welding set
Checks before starting work:
1. Clean the machine by cotton waste.

2. Check the pressure of argon gas in the cylinder.
3. Check the water in the radiator if necessary top up for the cooling.
4. Check the earth of the welding set.
5. Check the working of the welding torch.
6. Switch on the welding set and check the voltage.
7. Check the flow of argon in the flow manometer.
After stopping work:
 Close the argon gas cylinder valve.

 Keep the welding torch in the proper place of the welding set.
 Switch off the power supply to the machine from the main witch.

21-03-2006
PAGE 1 OF 1
TITLE: Preventive maintenance of drilling REV. NO.00 DATE:
machine
1. Clean the machine by cotton waste.

2. Check the level of lubricating oil, top up if required.
3. Apply grease and oil in the rotating and reciprocating parts.
4. Switch on the motor and check the working of clutch and slide movement.
5. Check the working of pneumatic cylinder.
 Close the air supply valve.

21-03-2006
PAGE 1 OF 1
TITLE: Preventive maintenance of braiding REV. NO.00 DATE:
machine
1. Clean the machine Segments by cotton waste .

2. Check the level of lubricating oil, should not be below the min level marked.
3. Apply oil on the Segments
4. Check the condition of the carriers and related parts.
5. Apply the grease and oil on the caterpillar moving and rotating parts.
6. Switch on the motor and check the movement of carrier and caterpillar.
Note: in case of any problem with regards to the above machine report to the production
manager

21-03-2006
PAGE 1 OF 1
TITLE: operating instructions o bobbin REV. NO.00 DATE:
winding machine.
THE OPERATING INSTRUCTIONS FOR THE ROBBIN WINDING MACHINE

ARE AS FOLLOWS:
1. Switch on the main switch.

2. Switch on the panel
3. Check the movement of pneumatic cylinder piston by doing the air compressor on.
4. Load the bobbins and switch on the auto switch
5. The r. p. m needed are to be set on the counter as per specifications.
6. Check the reciprocating movement of bobbin.
7. The wire winded spool of which winding is to be done is loaded on the machine.
8. Move the wire over the pulley and tie it with the bobbins.
9. Set the limit switch accordingly and on the auto switch, the bobbin should rotate and
also reciprocate.
10. Switch on the auto switch.
11. Machine should stop after completion of revolutions which are set on the counter.
12. In the same way winding in all the bobbins is done. Wire should be guided to prevent
the overlapping of wires.

21-03-2006
PAGE 1 OF 1
TITLE: operating instructions of corrugating REV. NO.00 DATE:
bobbin winding machine.
1. First of all on the power from the main switch and then switch on the panel and the
motor.
2. See whether the red light of sensor and proximity switch is glowing or not.
3. Reciprocate the moving plate and see its movement.
4. Move the die plate and pipe holder by manual switch.
5. Leave the moving plate in their opening position and load the die and pipe holder in
respective position.
6. Check the matching of die and pipe holder by their movement. No offset , no clearance
between dies
7. Now according to the size to be made, select the “O” ring and tight the water pressure
mandrel.
8. Put the seal holder having seal in it, put the water pressure ring and “O” ring and tight
the nut with the help of spanner.
9. Now set the centre of seals with respect to die pipe holder, moving with the help of
black sensor. Take one meter long tube and fit it in the pipe holder then set the
hydraulic pressure orientation of weld should be at about 90° to be die matching point
10. Bring the machine in the home position and start in after 2 and 3 corrugations are made
check the hose of and set the gap between the corrugations with the help of sensors.
11. After ½ mtr hose is made, check the number of corrugations and other parameters as
specified also check the quality of corrugation at die mating points no excess bump
should be observed. If they are as per specifications process is ok. And carry on the
manufacturing of hose

21-03-2006
PAGE 1 OF 1
TITLE: operating instructions of Braiding REV. NO.00 DATE:
machine.
1. Switch on the panel.

2. Now have a look at all the carriers, if there is any problem in springs etc, rectify it.
3. Now feed the bobbins in the carriers and lock.
4. Loosen the wires from the bobbins and take out from the carriers.
5. Load the mandrel in the cater pillar of size of which the braiding has to be made and
tight the caterpillar.
6. Tie all the wires to the pipe fixed before mandrel one by one.
7. Tie the pipe with the wire to the mandrel according to the size.
8. See if the cater pillar is loose or tight, if loose then tighten it. Wrap the woven cloth if
the belt slips and then on the auto switch.
9. Now stop the machine after nearly 1 meter of braiding is made and then check the angle
of braid as per the specifications.
10. If the angle is not according to the specifications then set the angle by increasing or
decreasing the rpm from the panel, if angle is ok then run the machine.
11. Start the oil pump so that segment, cam, gear are lubricated.

21-03-2006
PAGE 1 OF 1
TITLE: operating instructions of tubemill-1 REV. NO.00 DATE:
INSTRUCTIONS FOR OPERATING THE TUBE MILL ARE AS FOLLOWS:-
1. Set the rubber pads by opening the caterpillar as per the size of tube to be made.
2. Set the centerline of the Teflon plate and brass mould at the station.
3. Load the coil of specified size on the decoiler and tighten the fasteners.
4. Now decoil the portion of coil as needed and cut the starting end in taper form both
ends. Push the strip in the groove of Teflon plate till it reaches the welding station.
5. Load the mandrel pipe also on the machine according to size of the tube to be made,.
Now close the caterpillar.
6. On the main switch and welding set.
7. Press the hinge switch to move the tube forward and fit the brass bush according to the
size of the tube.
8. Tighten the pressure plate.
9. Grind the tungsten rod and fit in the collect of the welding torch.
10. Grinding of cone should be 3 times of the diameter of the
11. Set the distance in the welding electrode and the test piece.
12. Switch on the automatic switch off the panel.
13. The colour of the welding seam in the starting of welding will be black as no covering
of weld portion is provided. Cut a piece of tube, flatten it and do the cupping test.
14. If the reading of cupping test is more or equal to 10 then continue running the machine.
15. Now cover the welding are with glass wool and protective glass. The colour of welding
seam should be as per the reference sample.
16. welding acceptance criteria :
Color: As per displayed samples
Edge quality: Feel for burr / Mismatching / Sharp edge.

21-03-2006
PAGE 1 OF 1
TITLE: Maintenance of compressors REV. NO.00 DATE:
Daily checks before starting:
Clean the compressors properly by cotton waste or cloth.

Remove the waste water and air from the tank.
Check the pressure gauge whether it is indicating the pressure properly or not.
Check the suction value it is sucking the air or not.
Check the lubricating oil level if necessary top up to the level.
After stopping the work:
Close the air delivery value.

Switch off the power supply to the machine from the main switch.
Note: Annual contract given for the mechanical prevention of the breakdawn of the
compressors.

21-03-2006
PAGE 1 OF 1
TITLE: Operating instructions of ultrasonic REV. NO.00 DATE:
cleaning system.
CAUTION: The transducers are designed to operate only with the liquid load, therefore
care should be taken not to switch on the unit with less than 2” height of liquid in the tank
Carbon tetrachloride can never be used as the cleaning agent.
General operating instructions:
The tank should be filled with proper cleaning liquid up to about two-third the total depth
of the tank or upto overflow level. Switch on the generator. The level of the liquid is to be
adjusted to get maximum activity on the surface of the liquid.
In order to obtain the maximum ultrasonic cavitations the liquid inside the tank should be
heated up to 60 degree centigrade. This also helps to get effective cleaning. Care should be
taken to see that the tank is not overloaded with a large work piece or too many small parts
in lump.
It is important to allow the sufficient time for degassing of the liquid whenever thr fresh
solution is put in the tank.
Cleaning time varies between 5 to 10 minutes depending upon the contamination of the job.
1. Fill the liquid up to overflow level and mix the metal cleaning agent till the PH value of
9-11 is achieved.
2. Put on the heater. Set the temperature at 60 degree centigrade.
3. Immerse the hose in the ultra sonic bath.
4. Clamp the hose by hose clamp provided in the system if required.
5. Set the timer (0-60 mins) to the required cleaning time.
6. The time of exposure to ultrasonic action is determined on the basis of the nature of
contamination and cleaning liquid used.
7. Put On the UC and the filter.
8. UC and the filter will be cut off automatically after the set time.
9. Remove the hose and rinse it in the plain water by dipping.

21-03-2006
PAGE 1 OF 1
TITLE: Operating instructions of mechanical REV. NO.00 DATE:
corrugator
1. Switch On the machine. Keep the can in neutral position by actuating the inching
switch.
2. Fix the forming blade, forming bush, collet, holding blade and the wedge piece
according to the size of the hose to be made.
3. Set the pitch length at the rear screw rod according to the size of the hose.
4. Confirm the gap between forming bush and the forming blade is between 0.1 mm and
0.30 mm. if not adjust the ring nut at the rear of the spindle to arrive at the required gap.
5. Run the machine for one minute in the idle condition and lubricate the slides.
6. Check the level of the pipe lubricator if not proper then fill it.
7. Hold a 2 meter long tube and operate the machine.
8. Check the ID, OD , number of corrugations per metre/pitch as pet instructions. Adjust
the setting if deviation is observed.
9. Continue the production and keep checking all the parameters as per work instructions.

21-03-2006
PAGE 1 OF 1
TITLE: AUTHORIZED PERSONS FOR REV. NO.00 DATE:
QUALITY RELATED ACTIVITIES
THE FOLLOWING PERSONS ARE AUTHORIZED TO CARRY OUT THE QUALITITY

RELATED ACTIVITIES
S NAME DESIGNATION ACTIVITY

NO.
1 Heera lal sharma Stores astt. Reciept of incoming material.
2 Sandeep sharma Sr engineer QA Incoming material inspection.
3 Ashok sharma Engineer QA Incoming material inspection.
4 Sandeep sharma Sr engineer QA Issue of material from stores
5 Ashok sharma Engineer QA Issue of material from stores
6 Sandeep sharma Sr engineer QA In process inspection, coil inspection and slitting
inspection.
7 Ashok sharma Engineer QA In process inspection, coil inspection and slitting

inspection
8 Sandeep sharma Sr engineer QA Traceability of material, coil inspection and
slitting inspection.
9 Ashok sharma Engineer QA Traceability of material
10 Sandeep sharma Sr engineer QA Final inspection and type testing
11 Ashok sharma Engineer QA Final inspection and type testing
12 Sandeep sharma Sr engineer QA Visual inspecting of welding, issue of mtc,
calibration of instruments, testing of material
from outside lab.
13 Ashok sharma Engineer QA Visual inspection of welding
14 Gurdeep singh and Tubemill operator To carry out cupping test as per work
harun khan instructions and visual inspection.
15 RP Sharma Welder/Sr operator To carry out welding as per work instructions
and visual inspection.
16 Babu Ram Welder To carry out welding as per work instructions
17 Ram Kishan Welder To carry out welding as per work instructions
18 Karan singh Foreman To carry out welding as per work instructions
and visual inspection, traceability of material
19 Hariom sharma Welder To carry out welding as per work instructions
20 K.rajan Fitter To carry out testing as per work instructions
21 Dinesh Sharma Excise Astt. To carry out dispatch related activities

21-03-2006
PAGE 1 OF 1
TITLE: OPERDTING INSTRUCTION OF REV. NO.00 DATE:
TUBEMILL -2
THE OPERATING INSTRUCTIONS OF TUBE MILL-2 ARE AS FOLLOWS:
1) Set The rolls as per the size of the tube to be made.

2) Align the rolls in straight line by adjusting the spacers provided at the side of
the rolls.
3) Check the sizing rolls for proper alignment.
4) Change the nylon clamps of cutting machine to suit to the pipe.
5) Load the coil in the payoff stand such that the folding of burr faces upward.
6) Feed the sheet manually up to the first catching rolls.
7) Insert the welding bush into the holding block at the welding station.
8) Keep the machine in manual mode and switch ON the tube mill to feed the sheet
further up to the welding bush.
9) Switch on the welding machine, open the argon gas flow and switch on the
machine.
10) Adjust the gap at the weld seam by tightening or loosing the weld bush.
11) The colour of the weld seam in the starting will be black. Cut a piece of tube,
flatten it and do the cupping test. The cupping value should not be less than 10.
12) If the reading is more than 10 continue running the machine.
13) Now cover the welding are with the glass wool and continue production.
14) Cut the required length of the tube on the cutter.

21-03-2006
PAGE 1 OF 1
TITLE: ASSEMBLY OF COMPOSITE REV. NO.00 DATE:
HOSES
ASSEMBLY PROCEDURE:
1) First of all select the proper type of hose as per the code mentioned in the work
order.
2) Do the manchet marking with scales/gauges provided.
3) Make the manchet as per the marking by applying tape on the marked area cut
the outer and inner wires of the marked area .cut the inside fabric and now fouls
it outwards. The ends are now ready for fixing the couplings.
4) Prepare the mixture of epoxy and hardner in proper proportion/ratio as per
instruction no WI:GEN:32:01.
5) Fill the coupling with the mixture of epoxy and hardner.
6) Mount the coupling on hose end by rotating/screwing, ensure proper alignment.
7) Wires coming out from the coupling end should be spirally perfect.
8) Choose the swaging dies as per the size of the hose.
9) Before the swaging operation apply silicon free oil on the ferrule with the help
of brush.
10) Mount the coupling and Swage at the specified pressure. Ensure proper
alignment.
11) There should be no gap between the hose and coupling ferrule I.D.
12) Impression of wires must be felt over the ferrule.
13) Immediate cleaning is necessary to be done after the swaging. hose must be
checked from inside of the jointing ends for any epoxy flow, if epoxy is found
inside clean it.
14) Use turpentine oil for cleaning , do not use thinner.
15) After 24 hours of swaging operation subject the hose assembly for hydro
testing.
16) No pneumatic testing is done in composite hoses.
17) After hydro testing do the electrical continuity resistance test and ensure that the
resistance is less than 10 ohms.
18) Clean the hose assemblies by waste cloth and pack it for dispatch as per
instructions.
21-03-2006
PAGE 1 OF 1
TITLE: SWAGING INSTRUCYIONS REV. NO.00 DATE:
The maximum swaging pressure for swaging the composite hose assemblies as per the size of
the hose is as below:
SIZE NB (INCHES) SWAGING S STEPS MAXIMUM PRESSURE

(KG/CM2)
1” HALF SCREW TIGHT 70
FULL SCREW TIGHT
1-1/2” DO 70
2” DO 75
3” DO 80
4” DO 130
6” DO 180
8” DO 240
Note:
1) The Pressure gauge mounted on the swaging machine should be continuously

monitored so as to ensure that the pressure may not increase the specified
pressure mentioned above.
2) There should be no gap between the hose and coupling ferrule ID.
3) Wires coming out of the hose coupling should be spirally perfect.
4) No epoxy should flow from outside of coupling if so clean it immediately.
5) Impression of wires must be felt over the ferrule.

21-03-2006
PAGE 1 OF 2
TITLE: Type of Composite Hose and their REV. NO.00 DATE:
Applications
GENERAL INTRODUCTION:
Composite hoses are thermoplastic hoses consisting of:
i) An inner spiral of wire which is evenly pitched and tightly wound on to a

mandrel. The wire may be of stainless steel or carbon steel. Where carbon
steel is used it is galvanized.
ii) A multiply wall of thermoplastic films and reinforcing fabrics in suitable
proportions to give the required physical properties. The film content may
be built up of tubular films but shall in any case provide a complete seal.
The wall is designed to minimize twisting under pressure.
iii) An counter cover resistant to abrasion and weathering.
iv) A spiral outlet armoring wire, of stainless steel or galvanized carbon steel,
which is mid pitch to the inner wire and tensioned into position. The type of
hoses are as mentioned below.
1. MULTI-OIL BLUE: Multi oil tube hoses are designed for conveying
hydrocarbons, solvents, aromatics etc. these are of 3 types depending on the
pressure and application namely- light duty, standard duty and heavy duty.
These hoses are suitable up to the temperature range of -20deg c to 100deg c.
2. MULTICHEM BLACK: Multichem black hoses are designed for those
chemicals which do not affect the polypropylene lining and the polypropylene
coated steel inner wire. These are of 3 different types depending on the pressure
and application namely- light duty, standard duty and heavy duty. These hoses
are suitable up to the temperature range of 20deg c to 100deg c.
3. MULTICHEM GREEN:- Multichem green hoses are designed for those
chemicals which do not affect the polypropylene lining and the stainless steel
inner wire. These are of 3 different types depending on the pressure and
application namely: light duty, standard duty and heavy duty. These hoses are
suitable up to the temperature range of – 20deg c to 100deg c.
21-03-2006
PAGE 2 OF 2
Applications
4. MULTICHEM RED: Multichem red hoses are designed for those chemicals
and acids which do not effect the PTFE lining and the stainless steel inner wire.
These are of 3 different types depending on the pressure and application
namely: light duty, standard duty and heavy duty. These hoses are suitable up to
the temperature range of -20 deg c to 100 deg c.
5. MULTIVAPOUR YELLOW: Multivapour yellow hoses are designed

specifically for chemicals as well as for hydrocarbon vapor recovery on ships,
barges and in marine terminals. They can also be used to recover vapors in tank
truck and railcar applications. These hoses are suitable up to the temperature
range of – 20 deg c to 100 deg c.
6. MULTI-CRYOGENICS WHITE: Multicryogenic hoses are designed

specifically for use with fully refrigerated convey ants down to -50deg c on
ships, barges and in marine terminals. This application is including the
following media: ammonia, acetaldehyde, butadiene, butane, propane,
butylenes, diethylamide, ethylamine, ethylchloride, methylacetylene,
methylbromi depropane, propadiene, propylene, venylchloride, refrigerant
gases, Multicryogenics are also suitable for liquid ethylene at-105 deg c, liquid
ethane at-88 deg c. temperature range is -50deg c to + 50deg c

21-03-2006
PAGE 1 OF 1
Applications
The code is assigned to each hose which consists of 7 letters which are described as below:
First and second number of coding—gives the working pressure in bar.
Third number = material of inner wire WIRES:

1, G= GALVANISED
2, S= STAINLESS STEEL AISI316L
3, P= POLYPROP COATED
4, A=ALUMINIUM
Fourth number = material of lining LININGS:

1=POLYPROP FABRIC (10 BAR)
2= POLYPROP FABRIC (7 BAR)
3=PTFE (TEFLON)
7= HOSTAFLON
8= FEP
9= POLYAMIDE
Fifth number= Material of outer wire
Sixth letter= Material of inner wire
Seventh letter=Material outer wire
For example:14-331-SG-200, 14-denotes that the working pressure is14 bar, 3- denotes the
material of inner wire is AISI 316L, 3- denotes the material of lining is PTFE,1-denotes that
the material of outer wire is galvanized steel, s-denotes that the material of inner wire is AISI
316L, G-denotes that the material of outer wire is galvanized steel, 200-denotes that the size of
the hose is 200NB.

21-03-2006
PAGE 1 OF 1
TITLE: Epoxy Mixture preparation for REV. NO.00 DATE:
composite Hose Assemblies
QUANTITY OF EPOXY/ HARDNER MIXTURE PER COUPLING IN GRAMS
Size of White epoxy weight in grams Brown hardener Total weight of the
Hose assly (ARALDITE-AW136H) weight in grams mixture
(NB) (HY-991)
1” 15 5 20
1-1/2” 18.5 6.5 25
2” 26 9 35
2-1/2” 33 12 45
3” 60 20 80
4” 89 31 120
6” 350 122 472
8” 555 195 750
Note:
 Use electronic weighing scale for weighing the mixture.

 Set “0” on the weighing scale beore weighing the mixture.
 For one complete assembly the total weight of the mixture will be double.

21-03-2006
PAGE 1 OF 2
TITLE: Hydrostatic pressure test for REV. NO.00 DATE:
composite hose assemblies
Purpose: To conduct the hydrostatic test of composite hose assemblies (ref. std. BS5173:
SECTION 102.1:1991)
Test equipment: Hydrostatic pressure test pump fitted with calibrated pressure gauge of
suitable range. End fitting for fixing hose assembly to test pump on one end and closing the
other side of the hose assembly, a measuring tape.
Procedure for testing:

Fill the test piece with the test liquid (water), expelling all air, and connect to test equipment.
Close the value and apply the hydrostatic pressure at a uniform rate of increase. Measure the
pressure using a calibrated pressure gauge. When proof pressure tests are used to determine
leakage of test hoses or coupling, the rate of increase shall be between 0.75 bar and 1.75 bar for
hoses having design pressures up to 125 bar. The hose assemblies shall be hydro tested at 1.5
times the working pressure. Examine the test pieces during this period for evidence of leakage,
cracking, abrupt distortion indicating irregularity in material or manufacture.
Measurement of deformation under pressure: when tests for determining change in length,
change in external diameter and twisting are required , straighten the hose, lay it put
horizontally for inspection and apply a hydrostatic pressure of 0.7 bar. Make three reference
marks (A,B,C) on the outer surface of the hose, the middle mark B being made approximately
midway along the length of the hose, and the two outer marks ( A & C) being 250 mm from B.
Each mark shall consist of an arc on the circumference of the hose through which is drawn a
straight line perpendicular to the arc, the three straight lines being collinear. Maintain the initial
pressure of 0.7 bar and make the appropriate measurements as mentioned.
Apply the specified test pressure at the rate described above and maintain for 1 min before
repeating the test measurement which shall then be made as quickly as possible.

21-03-2006
PAGE 2 OF 2
TITLE: Hydrostatic pressure test for composite REV. NO.00 DATE:
hose assemblies
Change in length:
Measure the length between the two outermost reference marks ( A & C) with an accuracy of +
1 mm using the measuring tape at the initial pressure and at the specified test pressure. The %
change in length shall then be calculated as change in length= (L1-Lo/Lo)x 100
Change in external diameter:
The external diameter should preferably be determined from the measurements of
circumference made with an accuracy of 1mm using the measuring tape. Using the measuring
tape, measure the circumference at each of the three reference marks (A, B, and C) at the initial
pressure 0.7 bar and the specified test pressure. The % change in external diameter shall then
be calculated as: change in external diameter= (c1-co/co)x 100.
Twisting:
If twisting of the hose develops under pressure, the original lines forming the reference marks
will take up a helical pattern with the hose at the specified test pressure, project the straight line
in the length of the hose at the reference mark A until it intersects at c, the circular arc at
reference point C.
Then measure the length D of the circular arc CC to the nearest millimeter using the measuring
tape. The amount of twisting per meter, T expressed in radians will be T=Dx2¶/Co x Lo

21-03-2006
PAGE 1 OF 1
TITLE: Electrical continuity resistance test REV. NO.00 DATE:
for composite hose assemblies
Purpose: To measure the electrical continuity resistance of composite hose assemblies (ref.
std. BS5173: SECTION 104.2:1991)
General: In composite hose assemblies electrical continuity is provided between the end
fittings by means of continuous wire or wires bonded to each coupling. When the construction
of the hose is such that there are internal and external wires it is essential that the electrical
continuity of both wires be established the electrical continuity resistance should be less than
10

21-03-2006
PAGE 1 OF 1
TITLE: Determination of suction resistance REV. NO.00 DATE:
of composite hose assemblies (vacuum test)
Purpose: To measure the suction resistance of composite hose assemblies (ref. std.
BS5173:SECTION 102.9:1992,ISO 7233:1991)
Test equipment: A Suction pump, Vacuum gauge/U tube manometer:
Test Piece: A minimum test length, clear of the end fittings, of five times the nominal bore or 1
meter, whichever is greater shall be used or the complete hose or hose assembly if less than 1
meter long.
Procedure: fit the transparent airtight plates to both ends of the hose, one of which is
connected to a suction pump and gauge. Reduce the internal pressure in the hose within
60seconds to the specified test pressure and maintain this pressure for the required period,
which shall not be less than 10 min.
Whilst the reduced pressure is being maintained, examine the interior of the hose through one
of the transparent plates by illumination applied through the other plate and also examine the
exterior of the hose, for signs of delamination, indentation or collapse.
Each hose assembly shall be capable of withstanding a vacuum of 0.9 bar gauge for 30 minutes
resultant damage (ref std:BS5842:1980).

21-03-2006
PAGE 1 OF 1
TITLE: Determination of bend radius of REV. NO.00 DATE:
composite hose assemblies
Purpose: To measure the Bend radius of composite hose assemblies (ref.std.BS5842:1980)
Test equipment:
A hydrostatic pressure pump, a pressure gauge, a measuring tape.
Test piece: A composite hose assembly whose bend radius is to be measures.
Specified Minimum bend radius of composite hoses (ref std : BS 5842:1980)
NOMINAL SIZE OF HOSE (MM) MINIMUM BEND RADIUS (MM)

25 100
40 140
50 180
65 200
75 280
100 400
150 500
200 740
250 920
Procedure : Bend the hose assembly as per the size of the hose up to the bend radius as
mentioned above. The hose assembly should be capable of being bent at the working pressure
to the radii as mentioned above without any resultant damage. The bend radius is measured to
the surface of the hose inside the bend.

21-03-2006
PAGE 1 OF 1
TITLE: COIL SLITTING SPECIFICATION REV. NO.00 DATE:
FOR FLEX CONNECTOR
The width of sheet required for Flex Connector is as follows:-
S.No Size Slit Size Sheet Tolerance in

thickness Width
1 1-1/2” inner 119 0.25 +0.1
2 1-1/2” Outer 122.50 0.25 +0.1
3 1-3/4”inner 137.50 0.25 +0.1
4 1-3/4”outer 141 0.25 +0.1
5 2” inner 156.50 0.25 +0.1
6 2” outer 160 0.25 +0.1
7 2-1/4”inner 172.50 0.25 +0.1
8 2-1/4” outer 176 0.25 +0.1
9 2-1/2”inner 194.5 0.25 +0.1
10 2-1/2” outer 198 0.25 +0.1

11 3” inner 236.50 0.25 +0.1
12 3” outer 241.0 0.25 +0.1

21-03-2006
PAGE 1 OF 1
TITLE: Tube weld test equipment REV. NO.1 DATE:1-1-
2007
Sample of tube length required: 60 to 80mm
Specification and acceptance criteria for testing the weld quality of pipes
OD of Rubber Length of Size of Tube Tube OD (d) Minimum OD

bush Rubber bush NB after bulging
8.60 15 6 9.75 13.60
12.50 17 10 13.30 18.60
16 20 12 16.90 23.70
The minimum outside diameter is measured which is the acceptance criteria.

21-03-2006
PAGE 1 OF 3
TITLE: INTERLOCK FORMING REV. NO.00 DATE:10-
4-2009
Setup and operating instructions for interlock hose forming machine.

1. Check all the rollers for damage/presence of foreign material. Clean the roller or replace if
required.
2. Move the hose forming roller away from the center by adjusting the slide handle, until
sufficient apace is available for mounting the mandrel.
3. Select the required mandrel and mount it on the main spindle shaft.
4. Remove the front cover of the pay-off stand bring the expanding jaw to smaller diameter by
turning the hand wheel at the rear of the stand.
5. Select the required grade of strip and load it on the pay-off real.
6. Ensure that the real rotates at clockwise direction when the strip is pulled out.
7. Enroot the strip through the forming rolls up to the mandrel by turning the rolls in sequence
using 10 mm allen key.
8. Check the profile of the formed strip. The edge folding should be equal both sides at an angle
of approximately 45 deg.
9. If the profile is not OK, inform supervisor.
10. Feed the formed strip up to the bottom of the mandrel after allowing 180deg twist of formed
strip.
11. Bring bottom hose forming roller (Roller no.1) in contact with the strip and press against the
mandrel by rotating the handle of the roller slide.
12. Switch the control panel to manual mode and press the forward button to move the strip
forward.
13. Use screw driver to guide the strip and bring it to the front of right side hose forming roller
(Roller no. 2) and press the strip against the mandrel by roller no. 2.
14. In the same procedure, bring the strip through roller 3 and roller 4 and one circle is completed.
15. Keeping the mandrel to rotate in forward direction, guide the end of the strip to locate into the
second edge of the incoming strip.
16. Shift the panel into ‘run’ mode and run the machine in slow speed.
17. Check the alignment of the roller with the helix angle of interlock hose and adjust the angle of
the roller by adjusting the two allen screws on the wings of the roller slide.
18. Check the interlock quality after taking out a length of about 200 mm.
19. If the hose is too loose, increase the pressure of roller 1 and2.
20. If the hose is too tight, reduce the pressure of 1 and 2 and increase the pressure of 3 and 4.

21-03-2006
PAGE 2 OF 3
4-2009
FOR ALL HOSE TYPE TEST BEND RADIUS

Nominal size (IN MINIMUM MAXIMUM DOU UNPACKED
ACCDRDANCE INTERNAL EXTERNAL
WITH ISO DIAMETER DIAMETER
6708)
DN J D C/S
mm mm mm
6 5 8.3 70
8 7 10.3 80
10 905 13.5 90
12 11 17 105
15 13 21 130
20 18 26 150
25 23 32 175
32 31 39 205
40 37 49 250
50 48 59 305
65 62 76 365
80 75 89 400
100 97 111 485
125 120 136 625
150 144 163 805
200 192 216 1000
250 245 266 1200
300 295 317 1450
350 327 367 1525
400 378 418 1770
450 428 468 1990
500 478 520 2210

21-03-2006
PAGE 3 OF 3
4-2009
FOR ALL HOSE TYPE MINIMUM TENSILE STRENTH (N)

NOMINAL SIZE (IN ACCODRDANCE DOU UNPACKED
WITH ISO 6708)
DN C/S
Mm
6 500
8 800
10 1100
12 1400
15 1700
20 2300
25 2800
32 3500
40 4000
50 5000
65 6000
80 7500
100 9000
125 11000
150 14000
200 18000
250 22000
300 25000
350 28000
400 31000
450 34000
500 37000

21-03-2006
PAGE 1 OF 4
TITLE: STORAGE, PRESERVATION & REV. NO.00 DATE:
SAFEGURDING OF IMTE’s
Following general guidelines shall be considered while using IMTE’sea
Instrument Handling Storage Preservation Safeguarding

Family
-Before use, clean -store the instrument in -When instrument is not in
all surfaces from a clean area. Away from use for a long time, apply
dirt, dust, oil etc. dust & heat. oil on the moving parts to
ensure no rust/smooth
-Ensure that only -Do not over tighten the movement. NA
Vernier calibrated screws while storage
Caliper instrument is used (Where ever -As far as possible, keep the
applicable). instrument in original
packing.
-Before use, clean -Store the instrument in -When instrument is not in
all surfaces from a clean area, away from use for a long time, apply
dirt, dust ,oil etc. dust & heat. oil on the moving parts to
ensure no rust/ smooth
Micrometer -Ensure that only –Do not over tighten the movement.
calibrated screws while storage NA
instrument is used (wherever applicable). -As far as possible, keep the
instrument in original
packing.
-Before use, clean -Store the instrument in -When instrument is not in
all surfaces from a clean area away from use for a long time, apply
dirt, dust , oil etc. dust & heat. oil on the moving parts to
-Ensure that only -Do not over tighten the movement. NA
calibrated screws while storage
Height Gauge instrument is used (wherever applicable). -As far as possible, keep the
-Ensure smooth -Remove scriber/puppy packing.
movement of dial from the height
height gauge over gauge & store it
the surface plate. separately.

10.04.2009
PAGE 2 OF 4
Instrument Handling Storage Preservation Safeguardi

Family ng
-Do not scratch/rub the -Cover the surface -Apply oil on the surface
surface plate with any plate to avoid dust plate when not in use for a
sharp instrument. dirt gathering over it. long time & cover.
Surface Plate -Clean surface plate -Store the instrument -When instrument is not in NA
with TEC atleast twice in a clean area away use for a long time, apply
a week. from dust & heat . oil on the moving parts to
-Before use, clean all -Do not over tighten movement.
surfaces from dirt, dust, the screws while
oil etc. storage (Where ever -As far as possible, keep the
-Ensure that only packing.
calibrated instrument is
used
-Before use, clean all -Store the instrument -When instrument is not in
surfaces from dirt, dust in a clean area, away use for a long time, apply
,oil etc. from dust & heat. oil on the moving parts to
ensure no rust/ smooth
Bevel -Ensure that only –Do not over tighten movement.
Protector calibrated instrument is the screws while NA
used storage (wherever -As far as possible, keep the
packing.
-Before use, clean all -Store the instrument -When instrument is not in
surfaces from dirt, dust in a clean area away use for a long time, apply
, oil etc. from dust & heat. oil on the moving parts to
-Ensure that only -Do not over tighten movement. NA
calibrated instrument is the screws while
Thread plug used storage (wherever -As far as possible, keep the
gauge applicable). instrument in original
packing.

10.04.2009
PAGE 3 OF 4

Family ng
-Before use, Clean all -Store the instrument -When instrument is not in
surfaces from dirt, dust, in a clean area away use for a long time, apply
oil etc. from dust & heat . oil on the moving parts to
Thread Ring -Ensure that only -Do not over tighten movement. NA
Gauge calibrated instrument is the screws while
used storage (Where ever -As far as possible, keep the
packing.
-Before use, clean all -Store the instrument -When instrument is not in Applying
surfaces from dirt, dust in a clean area, away use for a long time, apply thread lock
,oil etc. from dust & heat. oil on the moving parts to on the adjust
ensure no rust/ smooth screws to
Snap Gauge -Ensure that only movement. avoid setting
calibrated instrument is disturbance
used -As far as possible, keep the
packing.
-Before use, clean all

surfaces from dirt, dust
, oil etc.
NA NA
Pressure -Ensure that only NA
Gauge calibrated instrument is
used
Voltmeter/ -Before use, clean all NA NA Apply

Ammeter surfaces from dirt, dust, Sticker/Tap
oil etc. on the adjust
screws to
-Ensure that only avoid setting
calibrated instrument is disturbance
used

10.04.2009
PAGE 4 OF 4

Family ng
-Before use, Clean all -Store the instrument -When instrument is not in
surfaces from dirt, dust, in a clean area away use for a long time, apply
oil etc. from dust & heat . oil on the moving parts to
Torque -Ensure that only -Do not over tighten movement. NA
wrench calibrated instrument is the screws while
used storage (Where ever -As far as possible, keep the
packing.
-Before use, clean the -Keep the -When the profile Projector
work stage plate and surrounding area is not using cover the whole
screen from dust and oil clean away from instrument properly NA
by dry cloth. dust & heat.
Profile
Projector -Ensure that only -Do not over tight
calibrated instrument is screws of micrometer
used

10.04.2009
WORK INSTRUCTIONS WI: ST:01
PAGE 1 OF 1
TITLE: Deterioration control REV. NO.00 DATE:
1. Date of receiving of material in stores is mentioned on DP test spray cans. At the time
of issuing such items old stock is issued first.
2. Conditioning of items is done as follows:
ITEM METHOD FREQUENCY
A Bearing Apply greas in consultation with 6 months

With maintenance Department
B. End Fittings/Flange
And other items which Antirust on inner surface 6 months
can get rust.
C. M.S nut, bolt, washer Antirust application

6 months.
And other small M.S/C.I
Items
III. Ensure that D.P. test spray cans stored are having shelf life(should not be expired)

10.04.2009
WORK INSTRUCTIONS WI: DRG:01
PAGE 1 OF 1
TITLE: Drawing control REV. NO.00 DATE:
The drawing number on all the drawings of end connections is given a 3 letter alphabet BHF
and the series of 5 numbers followed by the revision number which is different for fitting and
flanges: EX-BHF-12000-00
B- denotes the name of the company as Bengal industries.
H- denotes the item/product name as hose.
F – denotes the end connections as fittings.
The numbering for fittings start from BHF-10000-00 and onwards such as BHF-11000-00 ,
BHF-12000-00 etc.
The numbering for flanges starts from BHF-31000 and onwards such as BHF-32000-00, BHF-
33000-00 etc.
The drawing for the special end fitting for any specific customer requirement is assigned the
number as BHF/CUSTOMER NAME/ S. NO. OF DRG AND THE REVISION NUMBER.
The drawing of hose assemblies which are sent for customer approval are assigned the
numbering system as BHA/CUSTOMER NAME/ S.NO OF DRG AND THE REVISION
NUMBER. The customer reference is to be mentioned on the drawings. Where B- denotes the
name of the company.
H-denotes the name of the product as hose
A- denotes the assembly.
All the existing drawings will be taken as it is.

All the drawings should be duly approved by manager design/production and should br
checked and reviewed by Sr. Engineer QA

10.04.2009
PAGE 1 OF 1
TITLE: Operating instructions of bobbin REV. NO.00 DATE:
winding machine
THE OPERATING INSTRUCTIONS FOR THE BOBBIN WINDING MACHINE ARE AS

FOLLOWS:
1. Switch on the main switch.

3. Check the movement of pneumatic cylinder piston by doing the air compressor on.
4. Load the bobbins and switch on the auto switch.
5. The r.p.m needed are to be set on the counter as per specifications.
6. Check the reciprocating movement of bobbin.
7. The wire winded spool of which winding is to be done is loaded on the machine.
8. Move the wire over the pulley and tie it with the bobbins.
9. Set the limit switch accordingly and on the auto switch, the bobbin should rotate and also
reciprocate.
10. Switch on the auto switch.
11. Machine should stop after completion of revolutions which are set on the counter.
12. In the same way winding in all the bobbins is done. Wire should be guided to prevent the
overlapping of wires.

10.04.2009
PAGE 1 OF 1
TITLE: Operating instructions of REV. NO.00 DATE:
Corrugating machine
Instructions for operating the hydraulic corrugating machines are as follows:
1. First of all on the power from the main switch and then switch on the panel and the
motor.
2. See whether the red light of sensor and proximity switch is growing or not.
3. Reciprocate the moving plate and see its movement.
4. Move the die plate and pipe holder by manual switch.
5. Leave the moving plate in their opening position and load the die and pipe holder in the
respective position.
6. Check the matching of die and pipe holder by their movement.
7. Now according to the size to be made, select the “0” ring and tight the water pressure
mandrel.
8. Put the seal holder having seal in it, put the water pressure ring and “0” ring and tight
the nut with the help of spanner.
9. Now set the centre of seals with respect to die pipe holder, moving with the help of
black sensor. Take one meter long tube and fit it in the pipe holder then set the
hydraulic pressure.
10. Bring the machine in the home position and start it after 2 and 3 corrugations are made
check the hose od and set the gap between the corrugation with the help of sensors.
11. After ½ mtr hose is made, check the number of corrugations and other parameters as
specified. If they are as per specifications process is ok. And carry on the
manufacturing of hose.

21.03.2006
PAGE 1 OF 1
TITLE: Operating instructions of Braiding REV. NO.00 DATE:
machine
Instructions for operating the braiding machines are as follows:

2. Now have a look at all the carriers, if there is any problem in springs etc, rectify it.
3. Now feed the bobbins in the carriers and lock.
4. Loosen the wires from the bobbins and take out from the carriers.
5. Load the mandrel in the catter pillar of size of which the braiding has to be made and
tight the caterpillar.
6. Tie all the wires to the pipe fixed before mandrel one by one.
7. Tie the pipe with the wire to the mandrel according to the size.
8. See if the catter pillar is loose or tight, if loose then tighten it. Wrap the woven cloth if
the belt slips and then on the auto switch.
9. Now stop the machine after nearly 1 metre of braiding is made and then check the angle
of braid as per the specifications.
10. If the angle is no according to the specifications then set the angle by increasing or
decreasing the rpm from the panel, if angle is ok then run the machine.
Start the oil pump so that segment, cam , gear are lubricated.

21.03.2006
PAGE 1 OF 1
TITLE: Operating instructions of tubemill-1 REV. NO.00 DATE:
Instructions for operating the tube mill are as follows:
1. Set the rubber by opening the catter pillar as per the size of tube to be made.
2. Set the centerline of the Teflon plate and brass mould at the station.
3. Load the coil of specified size on the decoiler and tighten the fasteners.
4. Now decoil the portion of coil as needed and cut the starting end in taper form both
ends. Push the strip in the groove of Teflon plate till it reaches the welding station.
5. Load the mandrel pipe also on the machine according to size of the tube to be made.,
now close the caterpillar.
6. On the main switch and welding set.
7. Press the hinge switch to move the tube forward and fit the brass bush according to the
size of the tube.
8. Tighten the pressure plate.
9. Grind the tungsten rod and fit in the collect of the welding torch.
10. Set the distance in the welding electrode and the test piece.
11. Switch on the automatic switch off the panel.
12. The colour of the welding seam in the starting of wedding will be black as no covering
of weld portion is provided. Cut a piece of tube, flatten it and do the cupping test.
13. If the reading of cupping test is more or equal to 10 then continue running the machine.
14. Now cover the welding are with glass wool and protective glass. The colour of welding
seam should be as per the reference sample.

21.03.2006
PAGE 1 OF 1
TITLE: Instructions of DM water testing REV. NO.00 DATE:
Introduction and Definitions:
Acidic and basic are two extremes that describe a chemical property chemicals. Mixing acids
and bases can cancel out or neutralize their extreme effects. A substance that is neither acidic
nor basic is neutral.
The pH scale measures how acidic or basic a substance is. The pH scale ranges from 0 to 14. A
pH of 7 is neutral. A pH less than 7 is acidic. A pH greater than 7 is basic.
The pH scale is logarithmic and as a result, each whole pH value below 7 is ten times more
acidic than the next higher value. For example, pH 4 is ten times more acidic than pH 5 and
100 times more acidic than pH 6. The same holds true for pH values above 7, each of which is
ten times more alkaline (another way to say basic) than the next lower whole value. For
example, pH 10 is ten times more alkaline than pH 9 and 100 times more alkaline than pH 8.
Pure water is neutral. But when chemicals are mixed with water, the mixture can become either
acidic or basic. Examples of acidic substances are vinegar and lemon juice. Lye, milk of
magnesia, and ammonia are examples of basic substances.
Instructions for testing of DM water
1. By using the Litmus paper strip
 Dip strip in solution for 1-2 seconds; compare to color chart.

 Solutions must be aqueous (water based).
 For soaps, wet the strip first; oils cannot be tested.
 Deeply colored solutions can cause inaccurate readings.
 2 year shelf life: keep sealed & out of direct sunlight.
 Papers are non-bleeding so can be dipped for several minutes.
2. By using the universal indicator solution.
 Dip 0.2 ml solution for 10 ml liquid.

 Compare to color chart.
 Solutions must be aqueous (water based).

21.03.2006
PAGE 1 OF 1
TITLE: Specifications of strip Width ,thickness REV. NO.00 DATE
& material properties (for strip wound metal
hoses)
Interlock sheet thickness up to 2" = 0.25 mm to 0.3 mm x 15

Sizes above 2" to 3 " = 0.3 to 0.35 mm x 15.
Sizes above 3" to 4" = 0.35 to 0.4 mm x 30
Above 4" to 6" = 0.4 to 0.5 mm x 30
Above 6" to 8" = 0.5 to 0.6 mm x30
Above 8" to 10" = 0.6 mm x 30.
Tolerance on strip width is + 0.10 mm
Note:-Thickness of coil can be decided as per customer /Design Requirement.

Reference specifications: ASTM: A240, EN 10028-7
Material Properties
ASTM
304 0.08 0.03 2.00 0.75 0.045 18.00- 8.00- -- -- N-0.1
20.00 10.50 max
Type ASTM Mechanical Properties

UTS (N/MM2) YS(N/mm2) % Elongation, Hardness RB
min. min. min. max.
304 515 205 40 92

20.10.09
(inches) (mm)
1. ¼ 30+ 0.1 0.20
2. 3/8 41+ 0.1 0.20
3. ½ (c-3) 55.5+0.1 0.22
4. ½ (c-6) 52.5+0.1 0.20
5. 5/8 64+0.1 0.22
6. ¾(c-3) 81+0.1 0.22
7. ¾(c-5) 81+0.1 0.25
8. 1 81+0.1 0.26
9. 1-1/4 103+0.1 0.26
10. 1-1/2 128+0.1 0.26
11. 2 160+0.1 0.30
12. 2-1/2 207+0.2 0.30
13. 3 253+0.2 0.30
14. 4 318+0.2 0.31
15. 5 395+0.2 0.35
16. 6 466+0.2 0.40
17. 8 620+0.2 0.50
18 10 780+0.2 0.60
19. 5/16” 35+0.1 0.20

 Uniform burrs across width
Reference specifications : ASTM:A240, EN 10028-7

ASTM
304 0.08 0.03 2.00 0.75 0.045 18.00- 8.00- -- -- N-0.1
20.00 10.50 max
PAGE I OF 3
TITLE: Radioactive contamination test REV. NO. 00 DATE-
PURPOSE: To conduct Radioactive contamination test on coils, wire & end fittings
Test equipment:
Rad check meter RC705B with external detector probe.
Which checks for radioactive contamination (photons /Gamma Radiation) in steel/alloys/ iron
samples / scrap metal, when the meter front face is kept close to sample (almost touching). It is
a handheld instrument suitable for scanning manually.
‘Unit’ of measurement
Normally the units used in these meters globally are Sv (sivert). In India we have been using R
(Roentgen). This meters have FOUR modes of operation nSv/hr, μR/hr, CPS, CPM.
In the Rad Check Meters we may find μR/hr (micro roentgen / hour) & nSv/hr (nono sivert
/Hour)
μ = micro = 10-6
n = nano = 10-9
m = milli = 10-3
Sv & R
The SI unit of dose equivalent

1 Sv = 1 J /kg (one ‘Joul’ of energy deposited 1 kg of air)
Roentgen (R) : Is defined as the exposure that results in the generation of 1 electro static unit of
charge (2.0 g X 109 ion pairs) per 1 cm3 of air STP (0.001293 gms).
conversions between Sv & R

1 Sv/hr = 100R/hr
1mSv = 100mR/hr
1μISv = 100μR/hr
10nSv = 1 μR/hr
10μSv/hr = 1000μR/hr= 100 mR/hr
0.1 μSv/hr = 10μR/hr

13.05.2010
PAGE 2 OF 3
Preferred unit for measurement :-

% BG increases for higher contamination case is found to be high in nSV/HR mode relatively
compared to μR/hr mode of dose rate measurement. Hence in nSV/HR mode of measurement
should prefer.
Natural background radiation

In the nature exists background radiation, due to geo-structure, terrain, rocks, cosmic
Radiation flooring, tiles , walls etc. also contribute to background radiation levels. Natural
Background varies from place to place and could be in the range of (3-4) μR/h to (30-40) μR/h.
(0.03μSv/h to 0.4μSv/h). At a single location also, natural background varies and this is called
statistical variation. For practical purposes, we take the highest observed reading in a location
as natural background.
TEST PROCEDURE
Minimum mass & size of the sample to check for RaC using Rad Check Meter
A) It is advised for one to take a sample of mass of sample, at least of three Kg (approx) or
more but not less. Also the size & shape of the component should be large enough to cover the
complete front face of the detector probe / meter, so that detector face is covered by the sample
when touched. Higher the mass, results of inspection will be more authentic.If product is small
in size & less in wt, then put a few of these components together such that mass & front face of
the meter covering criteria, is met. This is important.
B) First record the background (BG) ( Typically 3 to 5 Background readings, averaging should
be alright) & then go to acquire mode & record BG. Now touch the meter to the surface of the
component under inspection if the reading shown goes 10 to 20% lower than the BG reading,
then the sample can be declared as clean
(If the reading is very close to BG & marginally less or equal to BG it is a suspected
Contamination case).

13.05.2010
PAGE 3 OF 3
Suspected contamination case (scc) & sure contamination case.
A) Suspected contamination case is a situation, when the Rad Check Meter reading is very
Marginally lower or same as the BG. This happens if the contamination levels are very low of
the order of 0.1 to 0.4 Bq/g. Under this condition take larger mass of 3/4 kg or much more &
touch the meter if the reading goes higher then it a sure contaminated case. Also initially itself
when you touch the component / part if the reading goes higher than BG, even slightly more,
then it is a sure Contamination case. Reading need not be 2 times or 1.5 time BG. It can be
slightly higher than BG..
Note:-Non-Ferrous Metals, such as copper, aluminum, zinc, brass & non-metals such as
plastics, wood etc normally not can get Radioactive Contamination

13.05.2010
PAGE 1 OF 1
TITLE: Helium Leak test REV. NO. 00 DATE-
PURPOSE: To conduct helium leak test on critical hoses & assemblies .
Test equipment:
Vacuum method - Tracer probe test
At the tracer probe test a spray gun is used to spray a fine jet of helium search gas at
areas suspected of leaking. Again the helium enters through leaks present at the
evacuated test object and the detector connected to it. The detector indicates if a leak is
present at the area the helium search gas is exposed to.
The tracer probe test can for example be used on seals, flange connections, weld seams
etc.
PAGE 1 OF 3
4-2009
Setup and operating instructions for interlock hose forming machine.

21. Check all the rollers for damage/presence of foreign material. Clean the roller or replace if
required.
22. Move the hose forming roller away from the center by adjusting the slide handle, until
sufficient apace is available for mounting the mandrel.
23. Select the required mandrel and mount it on the main spindle shaft.
24. Remove the front cover of the pay-off stand bring the expanding jaw to smaller diameter by
turning the hand wheel at the rear of the stand.
25. Select the required grade of strip and load it on the pay-off real.
26. Ensure that the real rotates at clockwise direction when the strip is pulled out.
27. Enroot the strip through the forming rolls up to the mandrel by turning the rolls in sequence
using 10 mm allen key.
28. Check the profile of the formed strip. The edge folding should be equal both sides at an angle
of approximately 45 deg.
29. If the profile is not OK, inform supervisor.
30. Feed the formed strip up to the bottom of the mandrel after allowing 180deg twist of formed
strip.
31. Bring bottom hose forming roller (Roller no.1) in contact with the strip and press against the
mandrel by rotating the handle of the roller slide.
32. Switch the control panel to manual mode and press the forward button to move the strip
forward.
33. Use screw driver to guide the strip and bring it to the front of right side hose forming roller
(Roller no. 2) and press the strip against the mandrel by roller no. 2.
34. In the same procedure, bring the strip through roller 3 and roller 4 and one circle is completed.
35. Keeping the mandrel to rotate in forward direction, guide the end of the strip to locate into the
second edge of the incoming strip.
36. Shift the panel into ‘run’ mode and run the machine in slow speed.
37. Check the alignment of the roller with the helix angle of interlock hose and adjust the angle of
the roller by adjusting the two allen screws on the wings of the roller slide.
38. Check the interlock quality after taking out a length of about 200 mm.
39. If the hose is too loose, increase the pressure of roller 1 and2.
40. If the hose is too tight, reduce the pressure of 1 and 2 and increase the pressure of 3 and 4.

13.05.2010

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BENGAL INDUSTRIES PVT LTD, FARIDABAD

Controlled Copy Serial Number

Controlled Copy Holder Mr.

S.NO. Title WI No.

Approved by Controlled by Issued by Issue:04 Effective date

S.NO. Title WI No.

BENGAL INDUSTRIES PVT LTD, FARIDABAD

S.NO. WI No. Rev. No. Date of Rev. Nature of amendment

Approved by Controlled by Issued by Issue:04 Effective date

S.NO. WI No. Rev. No. Date of Rev. Nature of amendment

Approved by Controlled by Issued by Issue:04 Effective date

COPY S.NO. CONTROLLED COPY HOLDER DEPARTMENT

WORK INSTRUCTION No. PLACE

Approved by Controlled by Issued by Issue:04 Effective date

S.NO. ABBREVIATION DETAILS

Approved by Controlled by Issued by Issue:04 Effective date

REFER STD: ISO10380:2003 Type 1, 2, 3, Claues 6.2

PURPOSE: To conduct pliable test on the flexible hose assemblies

Approved by Controlled by Issued by Issue:04 Effective date

The rate of flexing shall be from 5 cycle / min to 25 cycle /min

BEND RADIUS AND FORMER DIA AS PER ISO 10380:2003

DN PLIABLE TEST BEND RADIUS AND FORMER DIA IN MM

Approved by Controlled by Issued by Issue:04 Effective date

 Set the stroke length as specified in the table

 Set the counter to zero position.

 The hose movement will be 2x where x is equal to 4 DN or 125 mm whichever is

Approved by Controlled by Issued by Issue:04 Effective date

SPECIFIED BEND RADIUS AS PER ISO 10380:2003

Approved by Controlled by Issued by Issue:04 Effective date

1. Cantilever bend test rig.

2. hyd. Pressure pump with calibrated pressure gauge

3. Electronic digital counter

3. No lubricant shall be added before or during the test..

4. A hose assembly is said to be failed if

(a) Leakage of the hose and/ or

Approved by Controlled by Issued by Issue:04 Effective date

 The hose shall be subjected to a repeated flexing at a sinusoidal rate of from 3

For Type 1, 2 hoses:

Approved by Controlled by Issued by Issue:04 Effective date

SPECIFIED STROKE AS PER ISO 10380:2003

Nominal Size Flexibility Length

Approved by Controlled by Issued by Issue:04 Effective date

REF. STANDARD: ISO 10380-2003 CLAUSE 6.4.2, 6.4.3, 5.3.1.3, 5.3.1.4

Approved by Controlled by Issued by Issue:04 Effective date

REF. STANDARD: ISO 10380-2003 Clause 7.3

SCOPE: All the hose assemblies and hoses

1. Air Compressor of suitable pressure capacity

2. Suitable fixture for testing hoses/ assemblies

3. Calibrated pressure gauge of suitable range and least count

4. Water tank of suitable size to accommodate the hose assembly/ hoses.

 Unbraided hose/assemblies upto DN 100 shall be tested at a pressure of 1-

 The holding time should be minimum 2 min.

Approved by Controlled by Issued by Issue:04 Effective date

2. Put the hose assembly in the water tank.

3. Pressuries the hose assembly/ hose by air

5. Monitor the sample for bubbles.

6. Leakage if any can be detected when the bubbles comes out.

7. If no bubbles appear on the surface of water, the hose/hose assembly is said to

8. In case leakage is observed identify with red colour/ or white strip.

9. After rectification again test. If OK then send for further processing.

Approved by Controlled by Issued by Issue:04 Effective date

SCOPE: For all type of hose assemblies (Type 1,2,3)

REFERENCE STANDARD.: ISO 10380:2003 Clause 7.2.2.