(Southern Regional Office)It is a motor where winding as well as remaining space within the motor is...

BUREAU OF INDIAN STANDARDS (Southern Regional Office) Our Ref: 60/CM 1 6 Dec 2013 Subject: Preparation & Review of Product Manuals for Product Certification This has reference to CMD-I’s circular CMD-1/31 dated 11 Nov 2013 on the above subject. In this connection, the draft Product Manual in respect of IS 9283 allotted to SRO has been prepared. The same is attached herewith for hosting on the BIS Intranet for inviting suggestions and comments for a period of 15 days. The comments may be sent to SRO/ CBTO. (H.L. Upendar) DDGS Encl: a/a HITSD BIS HQ E. DEVENDAR Scientist G & Deputy Director General (South) Bureau of Indian Standards Southern Regional Office IV Cross Road, C.I.T. Campus Tharamani, Chennai - 600 113 Email: [email protected] Phone: 044 - 2254 2365 Fax: 044 - 2254 1087

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PRODUCT MANUAL Motors For Submersible Pump Sets IS 9283

PRODUCT MANUAL

ON

MOTORS FOR SUBMERSIBLE PUMPSETS

AS PER

IS 9283

BUREAU OF INDIAN STANDARDS NEW DELHI

Verified by: Approved by:

DOC. Name: MSP DATE: 25 NOV 2013 REVN. No. DATE: 25 NOV 2013

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AMENDMENT HISTORY

S.No Date of Amendment

Amendment No. Doc.No. Amendment Details

Need for Amendment



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FOREWORD

This product manual is prepared in order to maintain uniform certification procedures as per IS 9283. This manual consist of list of standards raw material , manufacturing process, and in- process quality controls , certification criteria , machinery list etc. While preparing this Manual , IS 9283 : 1995 (first revision-second reprint in July 1999) with four amendments are in practice. However IS 9283:2013 (second revision) has been published but yet to be implemented. The major changes incorporated in the second revision is value of Performance characteristics of two pole , three phase water filled submersible motors for 100 mm , 150 mm and 200 mm bore size, and value of Performance characteristics of two pole single phase 100mm water filled and two pole single phase 100 mm size, oil filled submersible motors. All other parameters are almost identical. Due care has been taken while preparing this manual BIS ,NEW DELHI



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Table of contents S.NO Section No Document detail

1 1 Product description

2 2 Raw material/Components

3 3 Manufacturing process/in process control

4 4 Certification criteria

5 5 Inspection and testing



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Section 1-Product description 1.1 Product description

Motors for submersible pump sets indicated in the standard IS 9283 are those type of motor which are used with submersible motor for bore hole and open well pumps handling clear, cold and fresh water at temperature not exceeding 33 deg cent. It is a motor which is completely filled with clear water or oil or is emulsion of water and oil. It is a motor where stator is encapsulated and filled with insulating compound. The remaining portion is filled with water or oil. It is a motor where winding as well as remaining space within the motor is filled with air or Suitable grade of oil. This motor are coupled with submersible pump sets are used in bore hole to lift and pump the water where normally other motors would not work.

1.2 IS. No / product title/ no of amendments:

Motors for submersible pump sets as per IS 9283:1995 with four amendments (At the time preparation of this manual IS9283:1995 is in practice. However IS 9283:2013 has been published ,but it is yet to be implemented and no STI has been prepared) 1.3 List of Raw materials/components/Test methods:

The materials indicated below are typical. The manufacturers may use material properties superior as per the properties of the material indicated. Verified by: Approved by:


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S.NO Name of the part Material Indian standards and grade

1 Bearing housing and base Grey cast iron IS 210 :1993 Gr FG-200 2 Motor shaft Wrought steel or chromium

steel IS 1873 : 1961 C-4013, IS 1570 (part 5):1985 Gr 04 cr or 12 cr 13 or 20 cr 13

3 Bearing bush Leaded tin bronze Or Resin bonded carbon metal Or Rubber Or Rubber-lined

IS 318 : 1981 , LTB 3 or LTB 4 or LTB 5

4 Rotor a)Lamination b)conductor core

Electrical sheet steel Electro grade copper

IS 648:1994 IS 612:1984

5 Stator a)Lamination b)winding wire 1)conductor 2)Insulation i)for water filled motor ii)for dry or encapsulated or oil filled or resin filled motor

Electrical sheet steel Electro grade copper PVC or with polymer Super enameled

IS 648:1994 IS 613:1984 IS 8783:1978 IS 4800(part 7):10970

6 Breather diaphragm Nit rile rubber - 7 Thrust Bearing Vulcanized fiber v/s

chromium steel or graphite v/s graphite or vulcanized fiber v/s bronze

-



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8 Cable gland Nit rile rubber

9 Cable a)conductor b)insulation

Electro grade copper PVC or Polymer and /or sheathing

IS 694:1990

10 Stator casting Gray cast iron or carbon steel or stainless steel sheet

IS 210:1993, FG 200 IS 1570 (part 5):1985 Gr 20 Cr13



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Section 1.4

CHECK-LIST FOR APPLICATION TI BE SUBMITTED BY APPLICANT TI BIS WHILE APPLYING FOR BIS LICENCE UNDER PRODUCT CERTIFICATION SCHEME OF BIS

The following check-list is required ti be submitted with all the applications for grant of BIS licence under the product Certification Scheme of BIS. Please tick ( ) in the relevant box. Whether applied under: Simplified Procedure Normal Procedure Note: Refer Bis website or details of “Simplified Procedure” and “Normal Procedure” for grant of licence.

No. Check-point Requirement Observations Page No.

General Is the application form completely filled? 1. Name &

Address Is the name and address of applicant (manufacturing unit applying for licence) same in the application as given in the attached document of Central/State Government

a. Has it been indicated whether the applicant is a large scale or small scale unit?

b. In case the applicant is a small scale unit, does the applicant hold valid Registration Certificate from theLocal /State authority or from a Chartered Accountant, and is the certificate attached

2.

Status of Applicant (Manufacturing Unit)

c. Has it been indicated whether the applicant is a Public Sector or a Private Sector company?

a. Has applicant recorded the applicable Indian Standard with correct title of the Standard?

3.

IS No &. Varieties

b. Where applicable, has applicant mentioned designation, grade, type, variety, size, etc., of the product for which the BIS licence is sought?

a. Whereapplicable, has theapplicant providedinformation regarding earlier BIS licence(s) held by them and / or cancelled in the past?

4

History

b. Where applicable, has the applicant provided information regarding BIS licences currently held by them?

5. Signature a.Is the application is signed by the CEO of the applicant? b. In case the application is signed by a person other than the

CEO, is the application signed by the authorized signatory of the applicant and his authorization is attached by the authorized signatory?

6. Machinery a.Does applicant possess requisite manufacturing infrastructure to manufacture the product as per the Indian standards?

b. Is installed capacity of production indicated in the application?

c. Does applicant have all machineries installed as per manufacturing process at the applicant’s manufacturing premises?

d. If answer to ‘c’ above is no, does the applicant outsource any of its manufacturing processes and possesses valid agreement(s) with other manufacturing unitsforthe outsourced processes and tracebility of material, thus produced, etc.?

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e. If answer to ‘d’ above is yes, does the applicant has any control oversuch outsourced activity? Are these outsoursed process will ensure testing the quality of final product for all requirements at the applicant’s manufacturing premises?

a. Does applicant possesses requisite test facilities in – house as per the relevant Indian Standard at its factory address?

b. Are valid calibration certificates for relevant test equipment attached are complete and valid at least 3 months after the dateof recording?

7. Test Equipment & Calibration

c. If reply to ‘a’ above is no. does applicant have arrangement with a BIS recognized outside lab for testing of the requirements for which it does not possess test facilities in- house? Is the consent letter as attached by applicant in this regard in order? Note: Relaxation in in- house test facilities may be allowed on submission of proper justification for requirements which are obligatory to get tested and for which frequency of testing, as is, normally, one month or more.

8. QC personnel Does the applicant employ qualified & experienced Quality Control (QC) personnel on permanent basis and possess documentary evidence to establish the same? Are the copies of the qualification certificates and appointment letters of the QC personnel are in order.

9. Raw Materials And Components

Where ever requirements for raw materials/components used in the manufacturing of the product are specified in the standard, do test reports/suppliers’ test certificates, as submitted by the applicant show that these requirements are met as per the standard?

10. Plant Layout Does copy of the plant (applicant manufacturing premises) layout clearly indicates location of manufacturing machinery, laboratory, office, workshop, amenities, storage area, etc?

a. Is the attached test report of in-house of from independent laboratory cover all requirements of the Indian Standard and is passing in such requirements?

11. Test Report(s)

b. In case the application is filled under “Simplified Procedure” is the test report(S), in original, as submitted a) from BIS or its recognized laboratories? B) the test report is not older than one month from the date of submission of application, c) covers all the requirements of the standard, and d) passes in all such requirements

12. Undertaking In case application is under simplified procedure, an undertaking shall be obtained from the applicant on his letter- head that the licence if granted against his application shall be put under Stop Marking by BIS if the verification sample(s) (any sample including the long duration test samples) drawn during visit of the BIS officer prior to grant of licence fail to conform to the requirements of relevant Indian Standards. The licensee shall take necessary corrective actions and inform the same to BIS along with fresh samples (of rating/size/variety which facilitates verification of corrective actions on the reported failures) manufactured after taking the corrective actions. The resumption of marking in such cases shall be allowed only on the basis of independent satisfactory Test Reports of the fresh were in long duration tests), In case the fresh sample drawn by BIS for independent testing fails, or the licensee does not inform corrective actions taken and does not offer improved samples within 1 month of the date of Stop Marking, the licence shall be processed for cancellation and no further chance would be given to the licensee.

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SECTION: 3.1. DESCRIPTION OF MAUNFACTURING PROCESS(ES)

1) All the Raw Materials like casting, copper wire, bearing bush shaft, stamping and readymade materials

are inspected for visual then sent for processing.

2) Casting like back housing, front housing and base are machined as per given drawing size, and inspected,

accepted materials are send to fitting section.

3) Bearing bush are pressed for insert in to the housing.

4) Stator stampings are checked for core length, OD,ID then sent to body fabricating, and after receipt of the

stator body inspected as per drawing and sent to, winding section.

5) Winding made with copper wire and insulating materials with help of former winding machines and sent

to inspection for insulation test, accepted lot again sent for fitting section.

6) Shaft materials are machined as per given drawing size, then inspected all the other sizes,, and accepted

lot sent for pressing section to insert the rotor.

7) Rotors inserted with shaft checked for air gap machining, process are completed than inspected size,

accepted material are send for dynamic balancing, after satisfactory result sent to fitting section.

8) Bearing are checked and sent for fitting section.

9) All the above material are received at one place called fittings section or assembly section were all the

fittings are assembled and motors are made as per drawing.

10) In order to ensure the quality para meters the motors are sent to the testing bed and tested for its quality

against IS 9283, if the sample passes all the accepted motors to painting section for final finishing.

11) Motors are painted and sent for packing and delivery section.

12) Name plates are fixed on the motor, then packed on the carton box for dispatch.



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Section 3.2: Infrastructure for production MOTOR FOR SUBMERSIBLE PUMP SETS AS PER IS 9283 S.No

Name of the machinery

1 Dynamic balancing machine for rotor balancing 2 Lathes 3 Painting booth and Painting gun 4 Hydraulic press 5 Weighing machines 6 Grinding machines 7 Compressor for painting 8 Drilling Machines 9 Winding machine with farmers and counters 10 Varnish impregnators 11 Cutting Machines 12 Fitting and assembly tables 13 DG set for power Backup

NOTE: The above list is only indicative and typical, General infrastructure required for various components / Sub assemblies of Motors for submersible pump sets. The manufacturer may use Superior machineries other than those specified above, which include digital controlled machineries and CNC machineries depending upon the volume, The machinery quantity may also be increased. The Manufacture may also procure machined components, sub assembly from the selected and approved source with suitable quality assurance system to ensure quality.

Verified by:

Approved by:


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SECTION4: CERTIFICATION CRITERIA 4.1 Identification of Critical requirement of the Indian Standard IS 9283

1. Dynamic balancing of rotor 2. For electric motor (clause 16.1)

a) Insulation Resistance test (both and after high voltage test) b) High voltage test c) Measurement of stator Resistance d) No load running of motor and reading of voltage , current power input and speed e) Locked rotor test f) Full load reading of voltage , current , power input and slip g) Performance characteristics h) Temperature rise test at rated and reduced voltage i) Leakage current test at rated voltage j) Reduced voltage running up test at no load to check the ability of motor to run up to

full speed on no load in each direction of rotation (for 3 phase motor only) k) Momentary overload test l) Vibration test

NOTE: k) and l) are upon agreement between the manufacture and purchaser

SECTION4.2: Scheme of testing and inspection (STI) for IS 9283-Document No :STI/9283/4 Jan 2008

Please see the attachment for STI 9283 Verified by: Approved by:


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Section 4.3: Marking fee rates Marking fee IS 9283:1995

Description Value Unit One kW L S Marking fee 34,000 S S Marking fee 29,000 Slab 1 rate 1.75 Slab 1 quantity 5000 Slab 2 rate 1.35 Slab 2 quantity 10000 Slab 3 rate 0.90 per unit, for rest of the unit. Enforcement date 20120806

Legends: L S- Large Scale Organization S S- Small Scale Organization

Section 4.4-Grouping Guidelines Certification of Motors for Submersible Pump sets is done on individual Motor rating basis. Please refer guideline Ref.No. CMD-III/16: 8034/14220/9079/9283 Dated.04/07/2011 Verified by:

DOC. Name: MSP DATE: 25 NOV 2013

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Approved by:

REVN. No. DATE: 25 NOV 2013


Section 4.5:Guideline for writing scope of Licence Product Description: Motor for Submersible Pump sets IS No : 9283 In addition the performance characteristics of the motor as declared by the manufacturer each rating of the motor will be attached to the scope of licence. The format for declaring the performance characteristic is attached with this manual under performance characteristics. However the declaration submitted by the manufacturer shall be within the limits specified in the IS 9283, This parameters to be ensured . IS 9283 specifies minimum full load speed ,maximum full load current, minimum starting torque in terms of the percentage of full load torque and nominal efficiency (in percent) of the motors suitable for bore size and maximum OD.

Section 4.6:Guideline for inclusion new varieties in licence The new varieties which are to be included in licence are to be independently tested at BIS approved laboratories and it should conforms to IS 9283 either through normal procedure or through simplified procedure . The varieties of the motors of all rating are independently tested for considering inclusion. The details of Normal procedure and simplified procedure for certification are available in BIS website www.bis.org.in under product certification. Verified by: Approved by:


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Section 4.7: Sample Size including guideline for drawl of separate samples when sample are required to be sent to different labs for testing One number of fully assemble Motors for submersible pump sets for each rating for motors offered for certification drawn for independent testing. As raw materials are only recommendedThere are no confirmatory test required for raw materials / components.

Section 4.8:Manner of sealing samples The sample drawn for independent testing shall be labeled for each sample with following Details. Motor rating/serial number/ date of manufacturing/ IS 9283. The label with above details shall be counter signed by the inspecting officer and attached with the sample and sealed with BIS seal for forwarding to I/T labs.

Section 4.9:Details of action taken of Remnants of samples after testing is completed Since the sample of Motors do not get damaged or destroyed or de shaped during the course of independent testing , the remnants of the sample can be taken back from the lab after completion of I/T for further use. Verified by: Approved by:


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Section 4.10: The Procedure to be followed for destroying/De shaping/Re cycling the Product that does not meet quality parameters: The product that does not meet the minimum requirements as per IS 9283 as declared by the manufacturer the firm shall investigate the cause of failure through necessary correction and corrective action on the motor. To ensure conformity after incorporating the correction the product will be re tested for conformity. If the product does not meet the requirement even after correction the product does not qualify for standard mark (ISI mark). The scheme of testing and inspection shall also be referred to and be strictly followed by BIS licensees during operation of licence. Verified by: Approved by:


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PRODUCT MANUAL

Motors For Submersible Pump Sets IS

9283

Section V: Inspection and testing Section 5.1: Packing material requirement ( to be available at factory at all time) for packing and dispatch the sample The Wooden crates or corrugated carbon boxes of adequate strength and size depending on the type of motor to be dispatched shall be available at all the time to facilitate packing of motors.

Section 5.2: List of Required test equipment/Facilities to be provided by CL as per note (a) of the annexure 2 of the note CMD-1/31 dtd 11 Nov 2013 Requirement and frequency of calibration: All the testing equipments shall be periodically checked and calibrated such calibration shall be maintained. The calibration may preferably done from NABL accredited laboratories if available or otherwise through laboratories having master references /standards having traceability to National standards The periodicity of the calibration decided upon usage, or once in a year for all test equipment except for pressure gauges, which is for once in six-month. Instruments recommended for calibration: Voltmeter ,Ammeter ,Wattmeter ,Flow meter , HV tester , Thermometer, Volumetric tank , Frequency meter , IR tester , Resistance Meter, Pressure gauge , Vacuum gauges, Spring Balances and Stop watch.



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PRODUCT MANUAL

Motors For Submersible Pump Sets IS

9283

Section5.3 : Status of test facilities in BIS labs or outside labs (OSLs) with testing charges and approximate time required for testing by BIS/OSLs The maximum time required for complete testing for one motor is 6-7 hours by BIS labs/OSLs. The status of testing labs by BIS labs or OSLs and their testing charges can be obtained From BIS websites www.bis.org.in under product certification. The detail outside laboratories and testing charges by OSLs are given in annexure enclosed for ready reference it is to be noted the testing charges are subjected to review and charges. Section 5.4: Basis for grant BIS licence The Grant of BIS certification marks license will be based only on independent testing of sample of the product for full conformity as per IS 9283wherever the test test facility are available at OSLs or BIS, In case the independent testing facility are not available either in BIS or at OSLs the competent authority of BIS will decide the mode of testing for conformity. Section 5.5: Details of tests to be carried out in the factory in case of

a) Applicant samples/verification samples: All the possible tests on the product to the extent of verifying the testing competency of the quality assurance personnel and to verify the working condition of different test equipment.

b) Surveillance samples/Market samples: All the possibilities to verify the continuing suitability/ testing competency of QA personnel and to check the satisfactory working condition of test equipment. In case of Market samples, complete testing is required to be done at BIS labs/OSLs.



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ANNEXURE TO GRANT OF LICENCE Licence No. – CM/L- Name of the Licensee: Declared Values for Motors for Submersible Pumpsets as per IS 9283: 1995

Sl.

No

.

Mo

tor

rati

ng

(

kW

)

Bo

re S

ize

(mm

)

No

. of

Ph

ases

Rat

ed V

olt

age

(V)

Rat

ed S

pee

d

(rp

m)

Win

din

g

Co

nn

ecti

on

No

min

al

Eff

icie

ncy

(%

)

Rat

ed F

req

uen

cy

(Hz)

Mo

tor

Typ

e

Du

ty T

ype

Mo

tor

Cat

eg

ory

Min

imu

m S

tart

ing

T

orq

ue

(%)

Max

. Cu

rre

nt

(A)

Max

. Lea

kag

e C

urr

ent

(mA

)

Min

. Su

b. (

m)

Scientist ‘F’ & Head

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List of BIS Laboratories

Date :- 26/11/2013

Lab Quantity Lab Type Testing Facility RemarksRecord not Found !

IS No. Testing Charges Remarks IS 9283 : 1995

Testing Facility:: C=Complete Test facility / P=Partial Test Facility/ N=No Test Facility

List of Outside Recognized Laboratories

Sl No.

Name of the Recognized Laboratory Lab Code Testing Charges

Remarks

IS Number :- IS 9283 - Motors for Submersible Pumpsets

1 Electronics and Quality Development Centre B 177/178, GIDC Electronics Estate Sector-25 Gandhinagar-382044 Gujarat Contact : Mr. L.S. Sharma, Director Tel : 079-23287119/20/22 Fax : 079-23287121

7118234 Upto 3.7kW-Rs.3,900/-, Above 3.7kW to 7.5kW- Rs.4,100/-, Above 7.5kW to 11 kW-Rs.5,350/-, Above 11kW to 15 kW-Rs.5,650/-, Above 15kW to 20 kW-Rs.5,650/-, Above 20 kW to 45 kW-Rs.8,000/-,

2 MSME Development Institute 386, Patel Road Ramnagar

6105534 Motors only: Rs.2,800/- upto 3.7kW; Rs.3,200/- above 3.7kW & upto 7.5kW; Rs.3,700/- above 7.5kW &

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Coimbatore-641009 Tamilnadu Contact : M. Palanivel, Deputy Director Tel : 0422-2233956, Fax : 0422-2230426

upto 11kW; Rs.4,500/- above 11kW & upto 15kW Pumpset:- Rs.6,500/- upto 3.7kW; Rs.7,000/- above 3.7kW & upto 7.5kW; Rs.7,700/- above 7.5kW & upto 11kW; Rs.9,200/- above 11kW & upto 15kW

3 NSIC Technical Services Centre 80 Ft. Road, Near Bhavnagar Road Crossing, Aji Industrial Area Rajkot-360003 Gujarat Contact : Shri N.K. Subramani, Deputy General Manager Tel : 0281-2387613,2387396 Fax : 0281-2387729

7104734 Combined Testing Charges with Pump as per IS 8034:-Rs.4320/- Upto 3.7kW; Rs.5040/- above 3.7kW to 7.5kW; Rs.5760/- above 7.5kW to 11kW; Rs.6120/- above 11kW to 15kW; Rs.6480/- above 15kW to 20kW; Rs.7200/- above 20 kW to 25kW; Rs.7920/- above 25kW to 30kW; Rs.8424/- above 30kW to 35kW; Rs.9000/- above 35kW to 40kW; Rs.9504/- above 40kW to 45kW; Rs.10800/- above 45kW to 50kW; Rs.12600/- above 50kW to 60kW; Rs.14400/- above 60kW to 70kW; Rs.17280/- above 70kW to 100kW; Rs.2880/- for overload vibration test of pump. For Motor only:- Rs.3888/- Upto 3.7kW; Rs. 4536/- above 3.7kW to 7.5kW; Rs.5184/- above 7.5kW to 11kW; Rs.5472/- above 11kW to 15kW; Rs.5904/- above 15kW to 20kW; Rs.6480/- above 20 kW to 25kW; Rs.7056/- above 25kW to 30kW; Rs.7560/- above 30kW to 35kW; Rs.8064/- above 35kW to 40kW; Rs.8640/- above 40kW to 45kW; Rs.9720/- above 45kW to 50kW; Rs.11304/- above 50kW to 60kW; Rs.12960/- above 60kW to 70kW; Rs.15480/- above 70kW to 100kW

4 Scientific & Industrial Testing & Research Centre

6104904 Rs.3800/- upto 3.7 kW, Rs.4100/- above 3.7 kW & upto 7.5 kw,

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83 & 84, Avarampalayam Road, K.R. Puram P.O. Coimbatore-641006 Tamilnadu Contact : Sh. K. Gunabal, Joint Director Tel : 0422-2562612,2560473 Fax : 0422-2562612

Rs.4700/- above 7.5 kW & upto 11.0 kW, Rs.5800/- above 11.0 kW & upto 15.0 kW, Rs.8000/- above 15.0 kW & upto 20.0 kW, Rs.9200/- above 20.0 kW & upto 25.0 kW, Rs.10400/- above 25.0 kW & upto 30.0 kW, Rs.11600/- above 30.0 kW & upto 35.0 kW, Rs.13400/- above 35.0 kW upto 40.0 kW, Rs.14300/- above 40.0 kW & upto 45.0 kW, Rs.15200/- above 45.0kW & upto 50.0

5 Electrical Research & Development AssociationP.B. No. 760, ERDA Road, Makarpura Industrial Estate Vadodara-390010 Gujarat Contact : Dr. M.K. Shah, JD&Quality Manager -Mob:09978940911 Tel : 0265-2642942,964,377 Fax : 0265-2648382

7101125 upto 3.7 kW-Rs.5590/-, 3.7kW to 7.5 kW-Rs.5835/-, 7.5 kW to 11 kW -Rs.8470/-, 11kW to 15 kW-Rs.5835/-, 15 kW to 20 kW -Rs.5835/-, 20kW to 45 kW-Rs.8470/- [25% discount for BIS]

(Southern Regional Office)It is a motor where winding as well as remaining space within the motor is...

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