UNDERSTANDING BIS CERTIFICATION TESTING SCHEME (Doc: STI/2830/4, September 2012)
Considering the confusion seen among induction furnace owners regarding the latest notification from BIS, providing the certification testing scheme, I have tried to explain some of the important clauses of the document in simple English to help the owners understand the requirements of BIS and appreciate the effort being put by BIS to improve the quality of our product and accordingly we should also help the government by improving and maintaining better laboratories.
In below part, first the clause has been written in black with its explanation provided in RED in simple English:-
1. LABORATORY - A laboratory shall be maintained which shall be suitably equipped and staffed where different tests shall be carried out in accordance with the methods given in the specification.
There is NO mention of any list of equipment (e.g. .spectrometer etc.) which is necessary to be kept in the lab. The clause only states that a laboratory should be maintained having sufficient equipment to conduct the test required for satisfying BIS criteria (Analysis for percentage of carbon, manganese, sulphur, phosphorus etc. is possible to be checked with chemical testing as already being done by almost every furnace unit).
7 LEVELS OF CONTROL
7.1.1 On the basis of test results, decision regarding conformity or otherwise of lots of steel billets ingots, billets, blooms and slabs to the requirement of the specification shall be taken as indicated below:
220.127.116.11 Chemical Composition (Ladle Analysis) : Chemical composition of billet ingots, billets, blooms and slabs obtained by analysis of one sample from each heat shall conforms to the requirements laid down in clause 6 of IS: 2830. Product analysis shall also be carried out on each cast. Drilling for check (Product) analysis shall be taken from the location as specified in clause 8 and as shown in Fig. 1 of IS: 2830.
18.104.22.168 Dimensions and Tolerances – All dimensional requirements as per Clause 11 of IS: 2830 shall be satisfied within the tolerances specified in Clause 12.
Clause 7 and Table 1 of the document states that two samples need to be taken for ladle analysis (i.e. during pouring of the heat, one at start and one at end of pouring) from each heat is to be taken– this does not mean that the entire heat needs to be poured in a ladle but only the quantity which is sufficient to check the chemical composition of the sample needs to be taken (maybe 1 or 2 KG).
Another sample needs to be taken from the final product by drilling a sample as mentioned in clause 8 of IS 2830:2012.
8.1 The sub-standard or defective materials, which do not conform to the specification shall be disposed off as scrap and the Standard Mark shall be defaced from the rejected material by cutting into pieces.
8.2 Records providing the detailed information regarding the rejection of material and the mode of their disposal shall be maintained. Such material shall in no case be stored together with that conforming to the specification.
Clause 8 provides details as how to dispose the rejected material. If any heat does not pass the specification in ladle analysis or final product testing then the heat after being cooled needs to be disposed as scrap and the BIS mark is to be defaced – it does not mean that the furnace process needs to be stopped in middle.
The records of the same are to be maintained as per clause 8.2 written above
12. PRODUCTION DATA- The licensee shall send to the Bureau as per the enclosed proforma a statement of the quantity produced, marked and exported by him and the trade value thereof for every quarter of the operating period of the licence. The statement is required to be forwarded to BIS at the end of every quarter of operative period.
Clause 12 states that a quarterly record of the entire quantity produced and their test results needs to be forwarded to BIS as per annexure 1 of the document.