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Doc: STI/3196 (Part1)/13, October 2016
1
भारतीय मानक ब्यरूो (कें द्रीय महुर विभाग 3)
हमारा सदंभभ : सी एम डी 3/16 : 3196 (Part 1) 18 नवबंर 2016
विषय : आई एस 3196 (Part 1) : 2013 (सशंोधन सखं्या 1 सहित) के लिए, पनुरीक्षित एस टी आई Doc: STI/3196 (Part1)/13, October 2016 का अनपुािन आई एस 3196 (Part 1): 2013 (सशंोधन सखं्या 1 सहित) के लिए पनुरीक्षित एस टी आई Doc: STI/3196 (Part1)/13, October 2016 अनपुािन िेत ुसिंग्न िै। पनुरीक्षित एस टी आई में clause 7.0 के अतंर्गत “Batch” के पररभाषा को सशंोधन सखं्या 1, अर्स्त 2015 के अनसुार सशंोधधत ककए र्ए िै। सिम प्राधधकारी ने अनपुािन िेत ुएस टी आई को अनमुोहित कर हिया िै। सभी िेत्रीय और शाखा कायागियों से अनरुोध िै की उपरोक्त हिशाननिेश का अनपुािन तत्काि प्रभाव से सनुनश्चित करें।
(अममत कुमार)
िजै्ञाननक सी (सी एम डी-3)
प्रमखु (सी एम डी-3)
सभी िेत्रीय /शाखा कायागिय/एम.ई.डी प्रनतलिपप : आई टी एस पवभार् , बी आई एस इंट्रानेट पर डािने िेत।ु
Doc: STI/3196 (Part1)/13, October 2016
2
BUREAU OF INDIAN STANDARDS
(Central Marks Department-3)
Our Ref: CMD-III/16:3196 (Part 1) 18 November 2016
Subject: Implementation of revised STI, Doc: STI/3196 (Part1)/13, October 2016 for IS 3196
(part 1): 2013 (with amendment No. 1)
Doc: STI/3196 (Part1)/13, October 2016 for IS 3196 (part 1): 2013 (with amendment No. 1) is
enclosed for implementation. In this revised STI definition of “Batch” under clause 7.0 is
modified in line with Amendment No. 1 August 2015.
The Competent Authority has approved the STI for implementation.
All ROs/BOs are requested to ensure the implementation of the above guidelines with immediate
effect.
(Amit Kumar)
Sc. C (CMD-3)
Head (CMD-3)
Circulated to: All ROs/BOs/MED
Copy to: ITS for hosting on Intranet
Doc: STI/3196 (Part1)/13, October 2016
3
SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF WELDED LOW
CARBON STEEL CYLINDERS EXCEEDING 5 LITRE WATERCAPACITY FOR LOW
PRESSURE LIQUEFIABLE GASES PART 1 CYLINDERS FOR LIQUEFIED PETROLEUM
GASES (LPG) ACCORDING TO IS 3196(Part.1) : 2013
(SIXTH REVISION)
(Including Amendment No. 1)
1.0 LABORATORY/TESTING STATION – Laboratory/testing stations commensurate with production
shall be maintained which shall be suitably equipped and staffed, where different tests given in the
specification shall be carried out in accordance with the methods given in the specification.
1.1 All testing instruments/equipments shall be periodically checked and calibrated. Records of such
checks/calibration shall be maintained.
1.1.1 Tensile testing machines shall be calibrated once in a year.
1.1.2 Various pressure gauges used shall be calibrated at least once in a month.
1.1.3 The pyrometer used for heat treatment furnace shall be calibrated once in every six months.
1.1.4 Testing instruments/equipments shall be carried out periodically from NABL accredited
calibration laboratories wherever they are available in the same city. In case where such
laboratories are not available, traceability to a National Measurement System (NPL) to be
ensured. All records of such calibrations to be kept.
2.0 TEST RECORDS - All records of tests and inspection shall be kept in suitable forms approved by BIS
2.1 Copies of any records or connected papers that may be required by BIS shall be made
available at any time on request.
2.2 For all stages of manufacture, the factory shall maintain appropriate controls and checks to
ensure that their product conforms to the various requirements of the Standard
3.0 QUALITY CONTROL The manufacturer shall maintain a Quality Control Department and shall
enforce proper inspection at all stages of manufacturing as per the schedules at Annexure A and Table 1, to
ensure that each cylinder is free from any manufacturing defects and comply in all respects to Indian
Standard Specification.
It is recommended that, as far as possible, Statistical Quality Control (SQC) methods may be used
for controlling the quality of the product during production as envisaged in this Scheme. [See IS
397(Part 1), IS397 (Part 2), IS 397(Part 3) and IS 397(Part 4)]. In addition, effort should be made to
gradually to introduce Quality Management system in accordance with IS/ISO 9001: 2008. All units
supplying cylinders to PSUs will obtain Quality Management System certification in accordance with
IS/ISO 9001: 2008 from BIS
Doc: STI/3196 (Part1)/13, October 2016
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4.0 ACCESS TO INSPECTION: As per Clause 12 of IS 3196 (Part 1):2013
4.1 The manufacturer shall supply the labour and appliances for such inspection and tests as are required
and for any additional checks desired by the Bureau.
5.0 STANDARD MARK – The Standard Mark, as given in Column (1) of the First
Schedule of the licence, shall be stamped on a non-detachable and non-pressure part of the
cylinder, provided always that each cylinder, so marked conforms to every requirements
of the specification.
5.1 OTHER MARKING: Each cylinder shall be marked with the following at the bung:
a) Serial number of the cylinder;
b) Manufacturer’s identification symbol;
c) Tare weight;
d) Year of manufacture;
6.2 Each cylinder shall also be marked with in accordance with Clause 20.1 and 20.2 of IS 3196
(Part1):2013 and any other marking as required in the approved drawing.
(Note: - the tare weight shall include the weight of the valve fitted to the cylinder).
7.0 CONTROL UNIT: For the purpose of this scheme, Batch and Inspection Lots shall be as
under:
Batch – A batch shall consist of finished cylinders not exceeding 3000 cylinders made
consecutively by the same manufacturer using the same manufacturing technique, to the same
design, size and material specifications on the same type of automatic welding machines and
subject to the same heat treatment conditions. A batch may contain material from more than one
cast. (Amendment No.1 to IS 3196 Part 1: 2013)
- Inspection Lots - for acceptance purposes the batch shall be divided into inspection lots not
exceeding 1000 cylinders. For selection of sample cylinders for either burst or mechanical tests,
each lot is divided into sub-lots of 250 cylinders (see Fig.1 of IS 3196 Part 1: 2013) The samples
taken for ‘mechanical or burst test’ shall be alternated between the mechanical and burst tests
(Clause 3.7.1 of IS 3196 Part 1: 2013)
7.1 The identity of each control unit/batch shall be maintained.
7.2 The tests as indicated in Annexure ‘A’ and Table 1 and at the levels of control specified
therein shall be carried out on the whole production of the factory covered by this Scheme and
appropriate records and charts maintained in accordance with paragraph 2 above.
Doc: STI/3196 (Part1)/13, October 2016
5
7.3 A certificate as per Annexure ‘B’ shall be issued by the BIS Inspecting Officer in respect of
every batch/inspection lots of cylinders marked with BIS Standard Mark
7.4 The period of manufacture/inspection/test shall be taken from the date of release of steel
to the date of final inspection/testing.
7.5 All pressing and cylindrical shells shall be examined for surface defects before any seam
is welded. No pressing or shell having defects beyond the acceptable limits shall be used.
7.6 Should any pressing or shell be of thickness less than the minimum specified thickness, all
output from the relevant batch of material shall be examined for minimum thickness, and any
pressing or shell found to be less than the specified minimum thickness shall be rejected and de-
shaped by pressing.
7.7 Before being fitted with valves all cylinders shall be thoroughly cleaned and dried internally.
7.8 Preparation for Despatch: Requirements as per Clause 23 to be complied with. The outside
surface shall be shot blasted and shall be given a protective coating as given in Cl.22.2 of
IS:3196(Part1):2006 before dispatch.
8.0 MATERIAL – As per Clause 4 of IS 3196 (Part) 1: 2013
9.0 DESIGN & FABRICATION - In respect of design, fabrication/ manufacture, the cylinder
shall conform to clause 6 to 10 of IS 3196(Part I): 2013
9.1 Welding consumables used shall be as per Clause 7.8 of IS 3196 (Part 1): 2013. To ensure
this, chemical analysis shall be arranged by the firm on the samples of drillings of weld wire and
flux combination. The tests may not be necessary if test certificate is received along with the
consignment (flux and wire). Nevertheless, samples shall be analysed once in every quarter as a
confirmatory check.
10.0 HEAT TREATMENT
10.1 After completion of all inspections satisfactory, the cylinders shall be punched with Sl.
Nos. before putting them for heat treatment.
10.2 All cylinders shall efficiently and uniformly normalized or stress relieved according to
Clause 11.1 & 11.2 of IS 3196 (Part 1): 2013. Localized heat treatment shall not be permitted
[(Refer to Clause 11.3 of IS 3196(part1):2013]
(NOTE: Care shall be taken to ensure the consistency of heat treatment cycle, the rise and fall of
temperature curve shall be within the declared temperature range. In case the temperature falls
below the lower limit, the furnace cycle shall be stopped and restarted only after attaining the
Doc: STI/3196 (Part1)/13, October 2016
6
requisite temperature. The records of heat treatment cycle and interruptions of cycle shall be
maintained.)
11.0 In respect of all other clauses of the specification the factory will maintain appropriate
control and checks to ensure that their product conforms to the various requirements of the
specification.
12.0 REJECTION: A separate record shall be maintained giving information relating to the
rejection of products which do not conform to the Indian Standard and the method of their
disposal. Such products shall in no case be stored together with those conforming to the Indian
Standard.
13.0 SAMPLES: The licensee shall supply free of charge, the sample or samples required in
accordance with Bureau of Indian Standards (Certification ) Regulation, from his factory or
godown. BIS shall pay for the samples taken by it from the open market.
14.0 REPLACEMENT: Whenever a complaint is received soon after the product with Standard
Mark have been purchased and used, and if there is adequate evidence that the product has not
been misused, defective product shall be replaced or repaired free of cost by the licensee in case
the complaint is proved to be genuine and the warranty period (where applicable) has not expired.
The final authority to judge conformity of the product to the Indian Standard shall be with BIS.
The firm shall have own complaint investigation system as per IS/ISO 10002
In the event of any damages caused by the product bearing the Standard Mark, or claim being
filed by the consumers against BIS Standard Mark and “ not conforming” to the relevant Indian
Standard, entire liability arising out of such non-conforming product shall be of the licensee and
BIS shall not in any way be responsible in such cases
15.0 STOP MARKING: The marking of the product shall be stopped under intimation to BIS, if
at any time, there is some difficulty in maintaining the conformity of the product to the Standard,
or the testing equipment goes out of order. The marking may be resumed as soon as the defects
are removed under intimation to BIS. The marking of the product shall be stopped immediately if
directed by BIS for any reason. The marking may then be resumed only after permission by BIS.
The information regarding resumption of marking shall also be sent to BIS.
13.0 PRODUCTION DATA: The licensee shall send to BIS as per the enclosed Proforma-1
authenticated by a Chartered Accountant, a statement of quantity produced, marked and exported
by them and the trade value thereof at the end of each operative year of the license.
Doc: STI/3196 (Part1)/13, October 2016
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.ANNEXURE ‘A’
STAGE INSPECTION FOR MANUFACTURE OF LPG CYLINDERS
1. MATERIAL: As per Table 1; levels of control
2. Manufacture / Assembly of Components
Pressings/Halves/
Cylinder shell
Valve Pad/Bung Joggle Joint Foot Ring Valve Protection
(Cl.10.3 IS
3196P1)
(Cl. 7.3 IS 3196
P1)
(Cl.10.2 IS 3196
P1)
(Cl. 9.3 IS 3196
P1)
a) Check Blanking
(circle making),
drawing/pressings
and trimmed
halves for surface
defects
(each piece -
visual)
a) Check
forgings for
surface defects
(each - visual)
a) check for
dimensions (each
piece - may be
checked by
gauging) and
surface defects.
(each piece -
visual)
a) check for
dimensions(hourly
5 pieces) and
surface
defects(each piece
- visual)
a) check for
dimensions
(hourly 5 pieces)
and surface defects
(each piece-
visual).
b) Check of
height to
maintain water
capacity
(first five pieces at
the start of
production and
two pieces every
hour. May be
checked by
gauging )
b)Each piece to be
checked for Finish
as per Annex B of
IS 3196(Part
1):2013
Dimensions to be
checked for 5
pieces
hourly
b) Check
for Marking
(hourly 5 pieces)
b) Check
for Marking
(hourly 5 pieces)
c) Degreasing
(each piece – in
case of any oil
trace, the piece to
degreased again)
c)welding: each
piece
c)welding: each
piece
c) welding; each
piece
3. Assembly & Manufacture
a) Inspect welding defects of the body, bung, foot ring and valve protection
b) Heat treatment (Ref Table 1; Levels of Control)
c) Select cylinders for acceptance test, bursting test and water capacity
d) Check for quality of grit blasting, protective metal coating and painting.
e) Check tare weight (with valve fitted to the cylinder)
Doc: STI/3196 (Part1)/13, October 2016
8
ANNEXURE ‘B’
Purchaser: _______________________ ____________________ Certificate No. : _______________________
Order No. : ___________________________________________ Date: ___________________
Batch No.: ___________________ Inspection Lot No.: ___________________________________________
Cylinder Description : _______litres water capacity. Two/three piece LPG Cylinder, working pressure _______
Test pressure _______ MPa . Manufacturer’s identification mark __________
This is to certify that the cylinders manufactured, inspected and tested as mentioned below during the period from
___________ to ________________at M/s ______________________________ meet the requirements of
specification IS 3196(Pt.1):2013, Drawing No. ___________ The cylinders have been fitted with ISI marked valves
Method of Manufacture Acceptance Test
1. Welding process : Sl. No. of Cylinders:
2 Method of Support: : Joggling
3 Heat treatment : Normalized/Stress Relieved at _____ ºC for___ Mints.
INSPECTION Min Max
The cylinders have been inspected and Yield stress
Tested in accordance with scheme of (MPa)
Testing and inspection attached with Tensile Strength
BIS licence no. CM/L-____________ (MPa)
Percentage elongation
Material for Cylinder: IS 6240/IS 15914
TESTS
Hydrostatic Test : Satisfactory
(Test Pressure___________Mpa )
Pneumatic leakage test : Satisfactory
(Test Pressure ____________ Mpa ) Bend Test
Face : Satisfactory
Bursting Test : Root : Satisfactory
Sl. No. of Cylinders Macro Examination
Burst Pressure ( Mpa): Min.- Max.- Body : Satisfactory
Cylinder bursted without fragmentation Neck : Satisfactory
Nominal Hoop Stress( Mpa) Min. Thickness: ___ mm
____________________________________________________________________________________________
Cylinder Nos. _______________ to____________ of ______________ batch are covered under Acceptance test
cylinder no. ___________ and burst test cylinder no. ________ of ___ batch. These have been heat treated in the
same manner and manufactured from steel of similar chemical composition and mechanical properties which had
been produced by same steel manufacturer
_____________________________________________________________________________________________
QUANTITY INSPECTED : Cylinders Serial No. from ____________ to _____________inclusive
Serial No. of REJECTED CYLINDERS ___________________________________
TOTAL No. of Cylinders Passed __________________________________________
(Signature) INSPECTING OFFICER
Name & Designation of the Bureau of Indian Standards
Officer representing the Company
Doc: STI/3196 (Part1)/13, October 2016
9
PROFORMA - 1
PROFORMA FOR OBTAINING PRODUCTION DETAILS
Period covered
Name of Licensee
CM/L No.
Name of Articles (s)
Grade/Type/Size/Variety/Class/Rating IS No.
1.1 Brand/Trade/Name(s) of BIS Certification Marked Products
2.0 Total production of the articles(s) Licensed for certification marking
2.1 Total production of the article(s) Conforming to Indian Standard
3.0 Production covered with BIS Certification Mark and its
Value : a) Quantity
b) Value (Rs.)
3.1 Brand Name used on production covered under BIS Certification Mark
3.2 Calculation of marking fee on unit-rate basis; Marking Fee per unit
a) Unit
b) Quantity covered with BIS Certification Mark
c) Marking fee rounded off in whole rupees as obtained by applying unit rates given in (a)
on quantity given in (b)
NOTE: In case a clause is not applicable, suitable remarks may be given against it
4.0 Quantity not covered with BIS Certification Mark. If any,
reasons for such non-coverage
4.1 Brand Name under with non-certified goods were sold
5.0 Quantity Exported with BIS Standard Mark and its value
5.1 Brand Name under which BIS Certified goods are exported
6.0 Authentication by Chartered Accountant
Doc: STI/3196 (Part1)/13, October 2016
10
Welded Low Carbon Steel Cylinders Exceeding 5 Liter Water Capacity for Low Pressure
Liquefiable Gases Part 1 Cylinders for Liquefied Petroleum Gases (LPG) according to IS 3196 (Part
1): 2013
Table 1; Levels of Control
Clau
se
Requirement Test Method Levels of Control Remarks
Claus
e
Reference Samples Lot
size
Frequen
cy
5;6 Design and
Drawing
5;
6
IS 3196
Part1:2013
-Drawings shall be
approved by statutory
authority
- Agreed finished
thickness shall not be
lower than that
calculated as per Clause
6 of IS 3196 Part1:2013
4 Material
Material for
cylinder shell
4.1;
4.1.1;
4.1.2
IS 3196
Part1:2013;
IS 6240;
IS 15914
Each consignment of
material to be supported
with manufacturer’s test
certificate heat/cast
wise.
Valve pad/bung 4.2 IS 3196
Part1:2013;
IS 1875;
IS 2062
-do-
Foot ring, stout
metal cap shroud
, stay plate
4.3 IS 3196
Part1:2013;
IS 1079;
IS 2062;
IS 6240
-do-
Protective ring 9.3.3 IS 3196
Part1:2013
-do-
Valves 9.1 IS 3196
Part1:2013;
IS 8737
Each consignment of material to be supported with
manufacturer’s test certificate
8;
12
Manufacture/
construction
IS 3196
Part1:2013
Pressings/
Halves/
Cylinder shell
8.4;
8.5;
12;
IS 3196
Part1:2013;
IS 9639
i) Each to be examined before closing in operation for
surface defects (external and internal). Only those
conforming to be used for further processing. Rejected
ones to be deshaped in such a way that it cannot be used
at any stage.
ii) 2% or more to be examined randomly for minimum
thickness before any seam is welded. If any piece is less
than the minimum specified thickness, the whole output
from the relevant batch of material shall be examined
Doc: STI/3196 (Part1)/13, October 2016
11
for minimum thickness and any piece which is less than
the specified minimum thickness shall be deshaped in
such a way that it cannot be used at any stage.
For above, batch of material is defined to mean
pressings/halves/cylindrical shells manufactured in a
continuous run.
iii) Circularity, profile regularity, straightness and
verticality shall be checked according to 8.5.1, 8.5.3,
8.5.4 and 8.5.5 of IS 3196 Part1:1993. Rejected ones to
be deshaped in such a way that it cannot be used at any
stage.
iv) The above examination shall be done after
degreasing.
Bung Hole
Making
8.5 IS 3196
Part1:2013
Each
piece
-In case of any non-conformance, the piece
to be rejected and to be deshaped in such a
way that it cannot be used at any stage.
-Each piece may be checked by gauging.
Welding of
cylinder and
attachments/fit--
tings
7;
10.1;
10.2;
10.3
IS 3196
Part1:2013
Each Cylinder Joggle joint shall be
according to 7.3 of IS
3196 Part1:2013
11 Heat Treatment 11.1;
11.2;
11.3
IS 3196
Part1:2013
Each cylinder i)Heat treatment shall
be done according to
11.1/11.2 of IS 3196
Part1:2013.
ii)Record of Heat
treatment cycle shall be
kept
iii)Localized heat
treatment not permitted
13 Radiographic
examination
(when required)
13.1,
13.2,
13.3;
10
IS 3196
Part1:2013
IS 3196
Part3:2012
As per 13.1; 13.2.1; 13.2.2 of
IS 3196 Part1:2013
In case of failure, to
follow procedure as per
10.4 of IS 3196
Part1:2013
14 Checking for
water capacity
14 IS 3196
Part1:2013
One
cylinder
Each
Inspect
—ion
lot
Every
100
cylinde-
-rs or
part
there of
In case of failure,
remaining cylinders to
be 100 % checked. The
rejected cylinder to be
scrapped by flattening/
deshaping. The
production to be
stopped and reasons of
failure to be
ascertained. Normal
Production shall be
resumed after corrective
actions taken and 100%
checking done for this
requirement for next
four inspection lots.
Doc: STI/3196 (Part1)/13, October 2016
12
15 Hydrostatic test 15
And
7
IS 3196
Part1:2013;
IS 3196
Part3:2012
Each
cylinder
The test may be carried
out using suitable
adapter at the bung. For
rejected cylinders, to
follow procedure as per
Clause 7.2 & 7.3 of
IS 3196 Part3:2012
16 Valve fixing and
Pneumatic
leakage test
16;
8
IS 3196
Part:2013;
IS 3196
Part3:2012
Each
cylinder
In case of failure, to
follow procedure as per
Clause 8.4 of IS 3196
Part3:2012
17
Fatigue
Testing/cycle
testing
17;
9.3
IS 3196
Part1:2013;
IS 3196
Part3:2012
One
sample
consis-
-ting of
three
cylinde
—rs as
per
17.1.1
of IS
3196
Part 1:
2013
One
inspect
--ion
lot
Type
Test
Type Test and required
to be done for initial
approval or whenever
there is a change in
design, raw material of
cylinder or asked by
BIS for specific reason.
In case of failure, to
follow procedure as per
9.3 of IS 3196
P3:2012. The test
sample shall be one
sample consisting of
three cylinder as per
17.1.1 of IS 3196
(Part 3): 2013. These
cylinders shall be from
one inspection lot
pertaining to batch not
exceeding 3000
cylinders.
17.2
Burst Test Under
Hydraulic
Pressure
17.2
&
9.1
IS 3196
Part1:2013
&
IS 3196
Part3:2012
Clause 3.7.1 and
Fig.1
Of
IS 3196 Part1:
2013
Each
batch
not
exceed-
-ing
3000
cylinder
In case of failure in
burst test, to follow
procedure as per clause
9.2 of IS 3196
Part3:2012
18 Acceptance Test
(Mechanical
Test)
18
&
5
IS 3196
Part1:2013
&
IS 3196
Part3:2012
In case of failure in
acceptance test, to
follow procedure as per
clause 5.7 of IS 3196
Part3:2012
19 Additional Test
(Impact and
Drop Tests)
Annex C of
IS 3196 Part1:2013
i)For cylinders manufactured from steel as per IS 15914
ii) Type Test for initial approval or whenever there is a
change in design, raw material of cylinder or asked by
BIS for specific reason
iii) samples shall be according to Annex C of
IS 3196 Part1:2013 from one inspection lot
10.1 Test for Handle
or other suitable
10.1 IS 3196
Part1:2013
One cylinder Each
inspect--
In case of failure,
remaining cylinders to
Doc: STI/3196 (Part1)/13, October 2016
13
arrangement ion lot be 100 % checked. The
rejected cylinder(s) to
be scrapped by
deshaping.
21 Colour
Identification
21 IS 3196
Part1:2013
Each cylinder
23 Preparation for
Despatch
23 IS 3196
Part1:2013
Internal cleaning
and drying
16.1
&
23.1
IS 3196
Part1:2013
Each cylinder
Grit blasting 23.2 IS 3196
Part1:2013
Each cylinder
Protective
Coating
23.2 IS 3196
Part1:2013
Each cylinder
Coating
thickness
23.2 IS 3196
Part1:2013
One
cylinder
Each
inspect
-
-ion lot
Every 50
cylinde--
rs
20.2 Tare weight 20.2 IS 3196
Part1:2013
Each cylinder (with valve fitted to the cylinder)