BUREAU OF INDIAN STANDARDS

(Western Region Office, Mumbai)

DRAFT PRODUCT CERTIFICATION MANUAL FOR COMMENTS

Our Ref: DDGW Sectt(PCO/RD) 23 Jan 2014

Sub: Preparation & review of draft manuals for product certification

This has reference to CMD circular CMD-1/31 dtd:11 Nov 2013 on the above subject. In this
connection, please find enclosed the draft product certification manuals prepared by WRO as indicated in
Annex-I

Kindly examine the draft product certification manuals and forward your comments on the drafts to
the ROs/ BO’S indicated against them in Annex-I and a copy of the comments may also be forwarded to at
wro@bis.org.in

Last date for comments: 3 Feb 2014.

Comments, if any, may please be made in the format as given below:

Sl. Name Clause/ Paragraph / Type of Comments Proposed Change

No. of RO / Sub-clause Figure / comment
BO Table (General /
Technical /
Editorial)

Note: Separate sheets may be attached in case comments are lengthy and cannot be incorporated in the table.

(Rosy Dhawan)
Sc ‘E’ & PCO (DDGW Sectt)
 PRODUCT MANUAL ON CERTIFICATION OF HIGH DENSITY POLYTHYLENE
PIPES FOR WATER SUPPLY

PRODUCT MANUAL ON CERTIFICATION

OF HIGH DENSITY POLYTHYLENE PIPES
FOR WATER SUPPLY

Prepared by Approved by
 PRODUCT MANUAL ON CERTIFICATION OF HIGH DENSITY POLYTHYLENE
PIPES FOR WATER SUPPLY

Amendment Sheet

Prepared by Approved by
 PRODUCT MANUAL ON CERTIFICATION OF HIGH DENSITY POLYTHYLENE
PIPES FOR WATER SUPPLY

TABLE OF CONTENTS

Section 1: Product Description

Description of Product
Latest Indian standard no with product title and no. of amendments
List of referred standards for raw materials / components and test methods
Check - list for submission of an application for grant of licence

Section 2: Raw Materials / Components

Section 3: Manufacturing Process & In Process Quality Controls

Description of Manufacturing Process

Intermediate Point of Control
Infrastructure for Production (Manufacturing Machinery)

Section 4: Certification Criteria

Identification of critical requirements of IS 4984

Scheme of Testing and Inspection
Marking Fee rates
Grouping Guidelines
Guidelines for writing scope of licence
Guidelines for Inclusion of new varieties
Guidelines for drawl of samples for independent testing
Manner of sealing of samples
Remnants of samples

Section 5: Inspection and Testing

Packing material requirement (to be available in factory at all times) for packing / dispatch of
samples
List of test equipments / facilities
Status of Test Facilities in BIS Labs and OSLs with testing charges
Grant of Licence will be based on
Details of test to be carried out in the factory

Prepared by Approved by
 PRODUCT MANUAL ON CERTIFICATION OF HIGH DENSITY POLYTHYLENE
PIPES FOR WATER SUPPLY

PRODUCT MANUAL ON CERTIFICATION OF HIGH DENSITY POLYTHYLENE

PIPES FOR WATER SUPPLY

Forward : The Product Certification Scheme of Bureau of Indian standards, now under Bureau
of Indian standards Act 1986 is an operation for more than 4 decades covering a wide variety of
products. The wide experience in the area has brought a fair amount of rationalization in
Certification process. This has resulted in the formulation of OMPC prescribing rules and
practices applicable to all products. Product related rules/guidelines are periodically issued to
cover specific requirements of different products. Still, in view of wide spread of certification
operations, differences are found in application of these guidelines in BIS Certification Offices in
different parts of the country. Therefore it has been decided to bring out sector manuals as
guideline documents covering Certification requirements of specific products / group of
products. This manual, one in the series, has been prepared to ensure uniformity in the
Certification practices in respect of HDPE pipes covered by IS 4984. This manual is strictly an
internal document indented use by the Certification Marks Officers of BIS.

Scope: This manual covers requirements for HDPE pipes from 16 to 1000 mm nominal
diameter of pressure rating from 0.25 Mpa to 1.6 Mpa in material grades PE 63, PE 80 & PE 100
for use for buried water mains and services and for water supply above ground, both inside &
outside buildings, vis-a-vis IS 4984: 1995. At the time of writing this manual, IS 4984: 1995 was
in force however standard is referred to as IS 4984 so that any revision to the standard does not
influence the manual.

Prepared by Approved by
 PRODUCT MANUAL ON CERTIFICATION OF HIGH DENSITY POLYTHYLENE
PIPES FOR WATER SUPPLY

Section 1: Product Description

5. Description of Product: HDPE is known for its large strength to density ratio. The mass
density of HDPE can range from 0.93 to 0.97 g/cm3. Although the density of HDPE is only
marginally higher than that of LDPE, HDPE has little branching, giving it stronger
intermolecular forces and tensile strength than LDPE. The difference in strength exceeds the
difference in density giving HDPE a higher specific strength. HDPE is resistance to many
different solvents and has a wide variety of applications. Pipes shall be classified by pressure
rating corresponding to maximum permissible working pressure at 30o C. Minimum required
strength of material in Mpa at 20o C for 50 years for different material grades as indicated at
table 1of IS 4984 and maximum allowable hydrostatic design stress are also important
parameters in design of the pipes.

6. Latest Indian standard no with product title and no. of amendments:

IS 4984: 1995, High Density Polyethylene Pipes for Water Supply – Specification, no of
amendments – 6

7. List of referred standards for raw materials / components and test methods;

IS No. Title
2530: 1963 Methods of rest for polyethylene moulding materials and polyethylene
Compounds
4905: 1968 Methods for random sampling
7328: 1992 High density polyethylene materials for moulding and ex-trusion (first
revision)
9845: 1985 Determination of overall migration of constituents of plastics materials
and articles intended to come into contact with foodstuffs - method of
analysis
10141: 1982 Positive list of constituents of polyethylene in contact with foodstuffs,
pharmaceuticals and drinking water
10146: 1982 Polyethylene for its safe use in contact with foodstuffs, pharmaceuticals
and drinking water

Prepared by Approved by
 PRODUCT MANUAL ON CERTIFICATION OF HIGH DENSITY POLYTHYLENE
PIPES FOR WATER SUPPLY

8. Check - list for submission of an application for grant of licence

1. APPLICATIOPN FORM
2. CERTIFICATE AUTHENTICATING MFG. PREMISES LIKE SSI CERTIFICATE
3. ACKNOWLEDGEMENT FROM MINISTRY OF INDUSTRIES (FOR LARGE SCALE
UNITS)
4. REGISTRATION CERTIFICATE-G.S.T.
5. REGISTRATION CERTIFICATE-C.S.T.
6. REGISTRATION CERTIFICATE-CENTRAL EXCISE
7. PARTNERSHIP DEED
OR
8. MEMORANDUM AND ARTICLES OF ASSOCIATION
9. AUTHORITY LETTER/ POWER OF ATTORNEY
10. SALE DEED/ LEASE DEED
11. ACCEPTANCE OF SCHEME OF TESTING & INSPECTION (STI)
12. ACCEPTANCE OF MARKING FEES
13. BRAND NAME DECLARATION PROFORMA (WITH REGISTRATION
DOCUMENTS (IF REGISTERED)
14. DECLARATION REGARDING MANUFACTURING MACHINERY IN CM/PF-305
15. DECLARATION REGARDING TEST EQUIPMENTS IN CM/PF-306
16. CALIBRATION CERTIFICATES
17. DECLARATION REGARDING SAMPLES TO BE OFFERED DURING
PRILIMINARY INSPECTION
18. CONSENT LETTER FROM BIS APPROVED LAB. (APPLICABLE WHERE SOME
TEST/S ARE CARRIED OUT FROM OUTSIDE LAB.)
19. RAW MATERIAL DETAILS
20. MFG. PROCESS
21. PROCESS FLOW DIAGRAM
22. LAYOUT PLAN OF FACTORY
23. TEST RESULTS OF SAMPLES TESTED DURING PRILIMIINARY INSPECTION
24. ROUTE MAP
25. RAW MATERIAL TEST CERTIFICATES
26. LAB RECORDS FOR ROUTINE TESTS
27. INTERMEDIATE POINTS OF CONTROL
28. APPOINTMENT LETTER, PHOTOGRAPH AND QUALIFICATION CERT. OF Q.C.I.
29. DECLARATION REGARDING WATER AND POWER SUPPLY
30. LIST OF DEALERS
31. SELLING PRICE DECLARATION
32. UNDERTAKING REGARDING SHIFTING AND OF MANUFACTURING
MACHINERIES AND TEST EQUIPMENTS
33. PRODUCT SPECIFIC DECLARATIONS ( WHERE APPLICABLE)

Prepared by Approved by
 PRODUCT MANUAL ON CERTIFICATION OF HIGH DENSITY POLYTHYLENE
PIPES FOR WATER SUPPLY

Section 2: Raw Materials / Components

HDPE granules
Master Batch

Section 3: Manufacturing Process & In Process Quality Controls

10 . Description of Manufacturing Process

Loading and drying process is done by mixture machine. HDPE granules and master batch are
mixed in mixture as per requirements, the required temperature can be set through panel and time
period can be controlled manually.

Extrusion process is carried out in the main plant which consists of die, sizer and pin. The
material from mixture is fed to the extruder machine which is set with recommended temperature
through panel and hence melting of raw materials is done which passes through die, sizer and pin
is formed into pipe of desired diameter and thickness. The hot pipe than passes trough cold water
in water cum vacuum tank, water is kept cool by cooling tower.

Subsequently marking is done by marking machine. The pipe is then pulled out by traction unit
as per the requirements and then coiled which can be cut by cutter as per required length.

Intermediate Point of Control:

--- Traction and take up speed,

---Vacuum pressure,
---Temperature of barrel and die zone,
---O.D. and thickness of pipe

11. Infrastructure for Production (Manufacturing Machinery)

1. Mixture
2. HDPE Pipe plant consisting of extruder die head with die, sizer & pin of required sizes
(a list of die, sizer, pin & bush shall be prepared and verified, an illustrative list for the
range 32 to 110 mm is enclosed)
3. Vacuum tank
4. Cooling tower
5. Water circulating pump
6. Air compressor
7. Automatic three liner machine (extruder)
8. Traction unit
9. Pipe winder (coiler)
10. Platform weighing balance

Prepared by Approved by
 PRODUCT MANUAL ON CERTIFICATION OF HIGH DENSITY POLYTHYLENE
PIPES FOR WATER SUPPLY

Prepared by Approved by
 PRODUCT MANUAL ON CERTIFICATION OF HIGH DENSITY POLYTHYLENE
PIPES FOR WATER SUPPLY

Section 4: Certification Criteria

12. Identification of critical requirements of IS 4984:

Width and depth of three equidistant stripes of blue colour as at clause 4.2 is treated as non-
critical requirement, all remaining requirements of IS 4984 are treated as critical.

13. Scheme of Testing and Inspection:

Doc: STI/4984/6, April 2004(copy enclosed)

Prepared by Approved by
 PRODUCT MANUAL ON CERTIFICATION OF HIGH DENSITY POLYTHYLENE
PIPES FOR WATER SUPPLY

Prepared by Approved by
 PRODUCT MANUAL ON CERTIFICATION OF HIGH DENSITY POLYTHYLENE
PIPES FOR WATER SUPPLY

Prepared by Approved by
 PRODUCT MANUAL ON CERTIFICATION OF HIGH DENSITY POLYTHYLENE
PIPES FOR WATER SUPPLY

Prepared by Approved by
 PRODUCT MANUAL ON CERTIFICATION OF HIGH DENSITY POLYTHYLENE
PIPES FOR WATER SUPPLY

Prepared by Approved by
 PRODUCT MANUAL ON CERTIFICATION OF HIGH DENSITY POLYTHYLENE
PIPES FOR WATER SUPPLY

Prepared by Approved by
 PRODUCT MANUAL ON CERTIFICATION OF HIGH DENSITY POLYTHYLENE
PIPES FOR WATER SUPPLY

14. Marking Fee rates:

Rs. 86.40 per unit (Unit = 1 Tonne) with minimum marking fee of
Rs. 29200/- for Small scale & Rs 36200/- for Large scale during an operative period of one year.

15. Grouping Guidelines – enclosed

Prepared by Approved by
 PRODUCT MANUAL ON CERTIFICATION OF HIGH DENSITY POLYTHYLENE
PIPES FOR WATER SUPPLY

Prepared by Approved by
 PRODUCT MANUAL ON CERTIFICATION OF HIGH DENSITY POLYTHYLENE
PIPES FOR WATER SUPPLY

16. Guidelines for writing scope of licence:

High Density Polyethylene Pipes for Water Supply

An illustration for sizes 32 to 110 mm for different material grades, pressure ratings and sizes
according to availability of die, sizer, pin & bush, samples offered as per grouping guidelines is
given below:

HDPE Pipes for following grades/sizes/pressure rating

PE 63 PN 2.5 DN 63 to 110
PE 63 PN 4 DN 40 to 110
PE 63 PN 6 DN 32 to 110
PE 63 PN 8 DN 32 to 110
PE 63 PN 10 DN 32 to 110
PE 63 PN 12.5 DN 32 to 110
PE 63 PN 16 DN 32 to 110
PE 80 PN 2.5 DN 90 to 110
PE 80 PN 4 DN 50 to 110
PE 80 PN 6 DN 40 to 110
PE 80 PN 8 DN 32 to 110
PE 80 PN 10 DN 32 to 110
PE 80 PN 12.5 DN 32 to 110
PE 80 PN 16 DN 32 to 110
PE 100 PN 6 DN 50 to 110
PE 100 PN 8 DN 40 to 110
PE 100 PN 10 DN 32 to 110
PE 100 PN 12.5 DN 32 to 110
PE 100 PN 16 DN 32 to 110

17. Guidelines for Inclusion of new varieties:

As per grouping guidelines, minimum of 20 to 25 nos for sizes up to 450mm and 10 to 5 nos for
sizes 500 to 1000mm. List of die, sizer, pin & bush shall be prepared as illustrated earlier and
verified in line with new varieties to be included. Samples shall be drawn for independent testing
as per grouping guidelines.

18. Guidelines for drawl of samples for independent testing:

Declaration of MFI & Density for all the three grades viz. PE 63, PE 80 & PE 100 shall be
obtained from the applicant before drawl of samples. Copy of illustrative test request is enclosed.

Prepared by Approved by
 PRODUCT MANUAL ON CERTIFICATION OF HIGH DENSITY POLYTHYLENE
PIPES FOR WATER SUPPLY

Our Ref. : RBO / Marks To, Date: 201304

M/s

Subject : Testing of Samples

Dear Sir(s),

1) We have pleasure in sending the sample(s) indicated below for testing by you. The test
may please be carried out in accordance with the Indian Standard(s) against the samples.

2) We are advising the party to deposit the sample(s) with you at an early date.

3) The testing charges will be borne by the applicant. We are advising the party to deposit
the testing charges with you early to honour the bill submitted by you in due course. The
test report(s), in triplicate, may please be sent to this office at an early date.

4) All Correspondence in this connection may please be treated as strictly confidential.

Copy or copies of Test Report(s), either in full or in part, should not, in any case, be
furnished to any person without our prior written consent.
5) The remnants of the sample(s), If any, may please be retained with you pending further
instructions from us.
6) Kindly acknowledge receipt of this letter as well as the sample(s) and let us have your test
report(s) at the earliest preferably....on..top..priority.
Thanking you,
Yours Faithfully

ANNEXURE – 1
Code Description Number of Relevant
Number(s) Test(s) Required Indian Standard(s)
Sample of 1 meter X 6 nos. each of HDPE pipes
Rajkot/ABB/201304 / for water supply of following designations For all tests as per
AS/01to08 01-PE 63 PN 4 DN 40, IS 4984: 1995
02- PE 63 PN 4 DN 110, (6 Amendments)
03- PE 100 PN 10 DN 32,
04- PE 100 PN 10 DN 110,
05- PE 100 PN 16 DN 32,
06- PE 100 PN 16 DN 110,
07- Sample of HDPE granules, PE 63
08- Sample of HDPE granules, PE 100

Prepared by Approved by
 PRODUCT MANUAL ON CERTIFICATION OF HIGH DENSITY POLYTHYLENE
PIPES FOR WATER SUPPLY

19. Manner of sealing of samples:

500gms of HDPE granules of the grades for which samples are offered shall be packed in
polyethylene bag, tied with thread and coded tag and wax sealed.

6 Samples of 1 mtr length shall be cut from the pipe, hole shall be drilled at one end of each
piece, all the 6 pieces are stacked on each other, thread or wire to be passed through holes of
each piece, both ends of thread or wire to be tied with each other and further with coded tag and
sealed with wax or lead seal and BIS seal.

20. Remnants of samples are non returnable, to be cut and disposed off.

21. The product HDPE pipes for Water Supply is under voluntary certification scheme. Product
that does not meet the quality parameters during regular production however generally meeting
the market requirements can be sold as non ISI product after defacing the marking on pipes. In
other cases the pipe to be converted into powder form and 10% of rework material can be mixed
with fresh lot of manufacture. Rejected pipes of more than 10% to be cut and sold as scrap.

Prepared by Approved by
 PRODUCT MANUAL ON CERTIFICATION OF HIGH DENSITY POLYTHYLENE
PIPES FOR WATER SUPPLY

Section 5: Inspection and Testing

22. Packing material requirement (to be available in factory at all times) for packing /
dispatch of samples:

1. Old HDPE/ jute bags

2. Thread / wire
3. Drill
4. Wax / lead seals
5. Tags with hole
6. Needle and thread for packing the sealed samples

23. List of test equipments / facilities: list is enclosed

Prepared by Approved by
 PRODUCT MANUAL ON CERTIFICATION OF HIGH DENSITY POLYTHYLENE
PIPES FOR WATER SUPPLY

Prepared by Approved by
 PRODUCT MANUAL ON CERTIFICATION OF HIGH DENSITY POLYTHYLENE
PIPES FOR WATER SUPPLY

24. Status of Test Facilities in BIS Labs and OSLs with testing charges:

Available on BIS intranet www.bis.org.in / intranet

Approximate time required for testing of samples: the maximum test duration is for 165 hours
for type test and hence entire testing can be completed within 7 days from the date of receipt of
samples by the lab depending on the capacity and availability of test facilities at the lab with
respect to no of samples under test and no of pending samples. Approximate time observed for
receipt of test report is generally 1 to 1.5 months.

25. Grant of Licence will be based on :

Independent testing bases

26. Details of test to be carried out in the factory:

Dimensional – O.D., wall thickness, length, ovality, MFR, Density, CBC, CBD, reversion test
visual appearance

Prepared by Approved by