You are on page 1of 88

skat

Resource Centre and
Consultancy for Development

RWSN

Rural Water
Supply Network

Guidelines for Quality Control
and Quality Assurance
of Afridev Handpump

Revision 2-2008

Quality Control Guidelines for Afridev Handpumps
REVISION 2 - 2008
These guidelines cover various aspects of Quality Control and Quality Assurance of the Afridev
Handpump.
This document results from work carried out for several years by the UNDP/World Bank Water and
Sanitation Program in partnership with SKAT, handpump manufacturers and inspection agencies in
several countries. The target group includes the manufacturers, quality assurance agencies and
purchasers.
Suggestions for improvements and requests for further information are welcome, and should be sent to
SKAT at the address given below.

First Edition:

SKAT - HTN Publication, 1995

Author:

Mr. G. Prakash (Industrial Division), SGS India Limited.

Reviewed by:

Mr. Erich Baumann, SKAT; Mr. Joe Fonseka and Mr. A.K. Mudgal, UNDP/World Bank
Water and Sanitation Program.

Revised:

K. Erpf

Photos:

Meera & Ceiko Pumps Pvt. Ltd. Hyderabad, India.

Drawings:

SKAT - RWSN,

Front page:

SKAT - RWSN,

Copyright:

SKAT – RWSN,
Provided the source ( UNDP-World Bank or SKAT - RWSN) is acknowledged, extracts
of this publication may be reproduced.

Distribution:

SKAT
Vadianstrasse 42
CH-9000 St.Gallen
Switzerland
Phone:
Fax:
E-mail:
or
URL:
or

1

+41 71 228 54 54
+41 71 228 54 55
info@skat.ch
karl.erpf@skat.ch
http://www.skat.ch
http://www.rwsn.ch

Quality Control Guidelines for Afridev Handpumps
Contents
Page No.
1.0 About the Guidelines …………………………………………………………………
4
1.1

Quality Control and Quality Assurance in Handpump Context

………….………...

4

1.2

About the Afridev Handpump ……………………………………………….…………
1.2.1 Description ……………………………………………………………………..
1.2.2 Assembly Option and Rationale for Selection ………………………………

5
5
7

2.0 Internal Quality Control …………………………………………………………….

11

2.1

Important Parameters of Raw Materials and Bought Out Items …………………… 11

2.2

General Checks during Handpump Production ……………………………………… 15

2.3

Procedure for Inspection of Raw Materials & Bought Out Items ………………….. 15
2.3.1 General Checks ………………………………………………………………… 15
2.3.2 Specific Checks ………………………………………………………………… 16

2.4

Specific Checks for Afridev Handpumps ………………………………………………
2.4.1 Checks for Raw Materials and Bought Out Items ……………………………
2.4.2 Stage Inspection during Production …………………………………………..
2.4.3 Checks on Components and Sub-assemblies ……………………………….

16
16
21
21

2.5

Inspection Check List for Main Assemblies ………………………………………….
2.5.1 General Checks ………………………………………………………………..
2.5.2 Specific Checks ………………………………………………………………..

33
33
34

2.6

Final Inspection and Marking Procedure ……………………………………………..
2.6.1 Checks during Final Inspection ………………………………………………
2.6.2 Marking Procedure ……………………………………………………………

36
36
37

3.0 External Quality Control (Quality Assurance) …………………….…………...

38

2

3.1

Pre-Requisite for Quality Assurance ………………………………………………….
3.1.1 Pre-qualification of Pump Suppliers ………………………………………….
3.1.2 Clearly Defined Purchase Order ………………………………………………
3.1.3 Pre-delivery Inspection …………………………………………………………

38
38
38
38

3.2

Procedure for Pre-delivery Inspection ………………………………………………..
3.2.1 Verification for the Effectiveness of the Internal Quality Control System ..
3.2.2 Sampling of Handpumps and Spare Parts for Pre-delivery Inspection …..

38
39
39

3.3

Specific Checks for Afridev Handpumps …………………………………………….
3.3.1 Checks for Important Attributes ………………………………………………
3.3.2 Dimension Check List for Afridev Handpumps and Spare Parts ………..
3.3.3 Performance Test ……………………………………………………………..
3.3.4 Inspection of PVC-U Riser Pipes ……………………………………………
3.3.5 Inspection and Marking Procedure ………………………………………….
3.3.6 Important Points to Remember ………………………………………………
3.3.7 Issue of Acceptance / Rejection Note ……………………………………….

40
40
41
50
50
50
50
51

4.0 End Inspection of Delivered Products (for customers) …………………………

52

4.1

General Checks …………………………………………………………………………

52

4.2

Specific Checks …………………………………………………………………………
4.2.1 Fabricated Parts ……………………………………………………………….
4.2.2 Cylinder Assembly …………………………………………………………….
4.2.3 Pumprod Bundles ……………………………………………………………..

52
52
52
52

4.3

Reporting and Follow-up ………………………………………………………………

52

Annexes
Page No.
Annex I

Format for Manufacturer’s Deviation Report

………………….………… 53

Annex II

List of Measuring Instruments for Afridev ………………………………... 54

Annex III

List of Standard Gauges for Afridev ………………………………….…… 54

Annex IV

List of Special Gauges and Templates for Afridev

Annex V

List of Special Testing Equipment for Afridev

Annex VI

List of Bending Tools for Afridev …………………………………………... 56

Annex VII

List of Welding Tools for Afridev …………………………………………... 56

Annex VIII

List of other Manufacturing Tools for Afridev …………………………….. 56

Annex IX

Examples of Manufacturing and Testing Jigs & Fixtures for Afridev …… 57

Annex X

Format for Evaluation of Afridev Handpump Manufacturers ….………… 60

Annex XI

The Purchase Order Format for Afridev …………….……………………. 62

Annex XII

Scale of Sampling for PVC-U Pipes (Double Sampling Method)

……..

66

Annex XIII

Format of Acceptance Note by Independent Inspection Agency ……...

67

Annex XIV

Format of Rejection Note by Independent Inspection Agency …….…..

68

Annex XV

List of Measuring Tools required for Customer’s End Inspection ……… 69

Annex XVI

Reference Standards used for Afridev Handpump Manufacturing

……………………… 55

……………………….….. 55

…… 70

Annex XVII Drawings of recommended Gauges and Templates for Afridev ………. 71

3

Quality Control process comprises a set of well defined operational techniques and procedures that are used to fulfil the requirements for quality. 1. Revision 1-1999 and • Packaging Guidelines for Afridev. c) Help buyers in formulating procurement procedures while ordering for hand pumps and spare parts. others can be attributed either to inadequate procurement procedures or insufficient understanding of the quality assurance requirements by inspection agencies.RWSN documents: • Afridev Handpump Specification. selection of manufacturers and pre-delivery inspection. Revision 1-1999. pre-delivery inspection of product at the manufacturer's works and inspection of goods at the customer's end. The quality. The pre-qualification and pre-delivery inspection are generally carried out by an Independent Inspection Agency (IIA) on behalf of a buyer. 4 . which assures a buyer that the product being purchased conforms to specification and requirements given in the purchase order. In other words it should perform as per defined performance parameters like discharge. internal quality control procedures from raw materials to finished product pre. • Moulding Guidelines for Rubber Components. formulation of a technically and commercially clear purchase order. In the context of a handpump. reliability and complete interchangeability of pump components (spare parts). Quality Assurance: The quality assurance is a process. This document should be read with the following SKAT . b) Help in minimizing differences in the interpretation of the product conformity requirements by manufacturers and inspection agencies. These guidelines have been developed with a view to: a) Help manufacturers in establishing an internal quality control mechanism at the factory level. Quality Control is that system of inspection and process control which a pump manufacturer is required to formulate to minimize variation from the required pump specification to achieve consistent quality and interchangeability of pump parts. operating effort. While most of the quality related problems can be attributed to lack of internal quality control mechanism at the factory level. Revision 5-2007. the manufacturing activities have to be performed in a controlled manner. • Afridev Injection Moulding Manual. In case of any discrepancy in this document. The manufacturing of a hand pump involves many interrelated activities.1. There are well defined norms and practices for carrying out pre-qualification survey. varies from manufacturer to manufacturer. procedure for the pre-delivery inspection and procedure for the customer’s end inspection. Edition 1992. This system of controlling the activities to produce a quality product is called Quality Control. The term “Quality” in the handpump context can be defined as "Totality of features and characteristics of a handpump that display its ability to satisfy stated and implied needs".requisites for quality assurance.0 About the Guidelines The Afridev Handpump is produced in several developing countries. the details given in the SKAT – RWSN Afridev Handpump Specification Revision 5-2007 shall prevail. In order to build quality in a product. They are aimed both at monitoring a process through stage inspections and eliminating causes of unsatisfactory performance at a relevant stages to ensure consistent conformance of a product to specification and also economy in production. however. This document covers main physical and chemical properties of raw materials and bought out items. This process comprises a number of stages namely pre-qualification of a supplier.1 Quality Control and Quality Assurance in Handpump Context The quality control & quality assurance in the context of the Afridev Handpump is described below: Quality Control: The term “Quality” literally means “degree of excellence”.

1 Description It is a reciprocating type deep-well handpump (see Page 6) suitable for lifting water from a depth of 10 to 45 meters from boreholes with casing sizes of 4”. government agencies. • Below ground parts a) Cylinder assembly including Plunger.2.The inspection at the customer’s end is generally carried out by the customer itself to ensure that goods received fully conform to the requirements given in the purchase order. 4. 1994. Revision 5-2007.5”. c) Rising main pipes with Centralisers. The Afridev Handpump Specification was first published by SKAT in 1989. 2003 and 2007. For more constructional details please refer to the SKAT – RWSN Afridev Handpump Specification.2 About the Afridev Handpump The Afridev deep-well handpump has been developed with the support from donors.and Footvalve. • Above Ground Components a) Pump head assembly with Cover. b) Pumprod assemblies with Pumprod centralisers. The Pump assembly can be broadly divided into a) Above Ground Components and b) Below Ground Components. 1998. extractable foot valve made of modern engineering plastics. d) Stand assembly. Available in public domain. research organisations and private companies. Several hundred thousand Afridev handpumps are now in operation in many countries in Asia and Africa. The pump can also be installed on a dug well. followed by revisions in the years 1991. c) Rod hanger assembly with Hanger pin and Bearing sets. 1. the design has aimed to adopt the Village Level Operation and Management (VLOM) concepts for easy and low-cost maintenance and suitability for manufacture in developing countries. This handpump has several novel design features like easy to replace plastic bearing bushes. 5 . b) Handle assembly with Fulcrum pin and Bearing sets. 5” and 6” (Nominal Bore 100. However. 115. 127 and 150 mm). suitable provision must be made for locating the pump stand and supporting the rising main to prevent its swinging during pump operation. 1. adjustable handle and non-corrodible below ground components.

6 .

. 5” or 6” (100.1... 7 Option A... • Option B.. g) Pumprod arrangements are available in four options: • Option A..2 Assembly Options and Rationale for Selection Options are available for certain assemblies. . straight Plastic riser pipes with straight sockets for solvent cementing..... Brass plunger and Plastic footvalve with threaded Fishing connector..... • Option B. Plunger/Footvalve arrangement Rising main arrangement . however..... • Option C.. Stainless Steel (AISI 304/316). Brass plunger with Brass footvalve with threaded fishing connector.. Cylinder with brass liner and footvalve receiver of Brass.. Option B. Cylinder with brass liner and footvalve receiver of Plastic.. Selection to be made depending on the casing pipe diameters of 4”... Pumprod arrangement .. d) Plunger / Footvalve arrangements are available in 3 options: • Option A.. • Option B.... with cast Eye and Hook connectors... galvanised..5.. • Option B.. Cylinder arrangement ... 115. Brass plunger and Plastic footvalve with Eye assembly (for fishing tool). Stainless steel pump rods AISI-304 are recommended for use in boreholes with corrosive water where pH value is below 6... b) Stand assemblies are available with two options: • Option A.. 4. f) Centralisers for Rising main pipes are available in four options... spout length 300 mm • Option B.. FRP rods (fibre glass rods) with Brass / Stainless Steel connectors.. • Option B. Pump stand . Option A. with threaded connectors.. • Option D.. Option A. Option A..... Carbon Steel.. The rationale for selection of options is discussed below (See also Options on Pages 8 to 10)... Plastic riser pipes with bell-ends for solvent cementing.... c) Cylinder arrangements are available in 2 options: • Option A. Either of the above can be used...... Carbon Steel pump rods are recommended only for use in boreholes having non-corrosive water....... 127 or 150 mm). Option A....... Selection is to be made based on the end use. spout length 580 mm... Stainless Steel AISI-316 is recommended where corrosive water conditions are severe.. • Option C... The buyers can select the pump with these options depending on the field requirements.5”... a) The Pump head assembly is available with different spout lengths: • Option A.2. Pump stand with three legs welded which are grouted directly into the concrete pump platform..... Pump stand with a Bottom flange used with an anchor assembly grouted into the concrete pump platform or fitted onto the well cover of a dug-well.... SKAT – RWSN recommends using the Standard Option which is: Pump head ... e) Rising main arrangements are available in 2 options: • Option A.. Stainless Steel.... with threaded connectors..

8 .

9 .

10 .

Table 1 Important Parameters of Raw Materials and Bought Out Items Equivalent Reference Material Chemical & Physical Properties Standards A Carbon Steel Chemical Properties as per ISO 630 Grade E185 Carbon Sulphur Phosphorus 1) Stock items: Plates.04% (max) 0.35%.040% (max) 0. square and round bars) : 0. sheets. sheets. angle iron.050% (max) Physical Properties Tensile Strength : 300 .640 N/mm² Chemical Properties as per ISO 2004 Class 3 Grade E235 4) Forgings Carbon Silica Manganese Sulphur Phosphorus : : : : : 0.540 N/mm² Chemical Properties as per ISO 630 Grade E235 2) Stock items: Plates.04% (max) Physical Properties Tensile Strength : 490N/mm(min) EN 10025/93 (S 235 JR) EN 10025/90 (Fe E 360-B) DIN 17100 (St 37-2) JIS 3101 (SS 400) BS 4360 (40 B) ASTM (A 284 gr) Chemical Properties as per ISO 559 Grade E355 5) Stock items: Pipes Carbon Sulphur Phosphorus Manganese : : : : 0. angle iron.2.040% (max) 0. Nuts & Washers.35%.50% (max) Physical Properties EN 10025/93 (S 185) EN 10025/90 (Fe 310-0) DIN 17100 (St 33) JIS 3101 (SS 330) ASTM (A 283) IS 2062 EN 10025/93 (S 235 JR) EN 10025/90 (Fe E 360-B) DIN 17100 (St 37-2) JIS 3101 (SS 400) BS 4360 (40 B) ASTM (A 284 gr) Tensile Strength : 340 .22% (max) : 0. the physical and chemical properties of raw materials and bought out items are summarised in Table 1. 0.055% (max) 0.040% (max) 0. angle iron. Pins 11 Chemical and Physical Properties Same as Table 1 – A1 above ISO 630 DIN 17100 IS 2062 .470 N/mm² Chemical Properties as per ISO 630 Grade E355 3) Stock items: Plates.25-0.055% (max) 1.640 N/mm² 6) Fasteners: Bolts. sheets. square and round bars) Carbon Sulphur Phosphorus Manganese : : : : 0. 0.1 Important Parameters of Raw Materials and Bought Out Items For ready reference.16% (max) 0.040% (max) 1.60% (max) Physical Properties EN 10025/93 (S 355 JO) EN 10025/90 (Fe 510-C) DIN 17100 (St 52-3 U) JIS 3101 (SS 490 B) BS 4360 (50 C) ASTM (A 633 gr) Tensile Strength : 490 .22% (max) 0.70% (max) Physical Properties ISO 4200 ISO 4019 DIN 1615 DIN 2458 IS 1239 Tensile Strength : 320 . For more information.050% (max) : 0. the reader is advised to refer to relevant specifications.60-0.15-0.0 Internal Quality Control 2.90%. square and round bars) Carbon Sulphur Phosphorus Manganese : : : : 0.20% (max) 0. 0.

07% (max) : 16.03% (max) : 0.Material Chemical & Physical Properties Equivalent Reference Standards Chemical Properties as per ISO 15510 B Stainless Steel X5CrNi 18-9 1) Stock items: Round bars (bright) Carbon Chromium Nickel Silicon Manganese Phosphorus Sulphur : : : : : : : 0.0% (max) : 2.11% (max) DIN 17400 .5% 1.5 .4401 IS 6603 AISI 316 Physical Properties Tensile Strength : 510 – 710 N/mm² X5CrNiMo 17-12-2 Chemical Properties Same as under 3 (Stock items) 4) Forgings Physical Properties Tensile Strength DIN 17400 – 1.4301 IS 6603 AISI 304 6) Fasteners Chemical and Physical Properties same as Table 1 – B1 above DIN 17400 .03% (max) DIN 17400 – 1.700 N/mm Chemical Properties as per ISO 15510 X5CrNiMo 17-12-2 3) Stock items: Round bars (bright) Carbon Chromium Nickel Molybedenum Silicon Manganese Phosphorus Sulphur Nitrogen : 0. 5% : 10.4301 IS 6603 AISI 304 : 500 .1.18.4301 IS 6603 AISI 304 12 .0% : 2.4401 IS 6603 AISI 304 : 510 .5% .5% 8.0% (max) : 0.10.0% (max) 0.1.0% (max) 2.1. 0 – 13.0 .710 N/mm 5) Sleeves Chemical & Physical Properties same as Table 1 – B1 above DIN 17400 .0% : 1.0 .3.07% (max) 17.045% (max) 0.045% (max) : 0.4301 Tensile Strength DIN 17400 .19.4301 IS 6603 AISI 304 Physical Properties Tensile Strength : 500 – 700 N/mm² X5CrNi 18-9 Chemical Properties Same as under 1 (Stock items) 2) Forgings Physical Properties as per DIN 17440-1.1.

07% (max) : 0.2.0% Arsenic (or Antimony) : 0.8 .79.35 – 4.3% (max) : 0.06% Lead : 0.0460:CuZn 20 AI2 Physical Properties Tensile Strength : 330 N/mm DIN 17660 IS 407 .) Copper Lead Iron Zinc 5) Fasteners Chemical and Physical Properties same as Table 1 – C1 above 13 DIN 17660 .0321:CuZn37 Chemical Properties as per ISO 426-2 CuZn 20 Al2 2) Brass sleeve (Liner) Copper Aluminum Lead Iron Arsenic (or Antimony) Phosphorus Zinc : 76.59.Material C Brass CuZn37 1) Brass sleeve (Liner) Chemical & Physical Properties Chemical Properties as per ISO 426-1 Copper : 62.50% : 0.0 .06% : 0.0 . collet etc.0 .0% : 0.0.02 .20% (max) Zinc : remainder Equivalent Reference Standards DIN 17660 .2.2.02 – 0.2.01% (max) : remainder DIN 17660 . receiver.06% Iron : 0.0.02 .05% (max) : 0.30% (max) Iron : 0.0470:CuZn 28 Sn1 : 56. connector.2.0 .90 – 1.30% Zinc : remainder IS 407 Chemical Properties as per ISO 426-2 4) Brass bar for components: (Plunger. footvalve.05% (max) Tin : 0.35% (max) : remainder DIN 17660 .0% : 1.73.0460:CuZn 20 AI2 Physical Properties Tensile Strength : 330 N/mm Chemical Properties as per ISO 426-2 CuZn 28 Sn1 3) Brass sleeve (Liner) CuZn 38 Pb4 Copper : 70.64% Lead : 0.07% (max) Phosphorus : 0.

BS 5350-P.6) and Polyacetal (POM Homopolymer) Tensile test: Destructive test (9500 Newton) on a few pieces per production batch. voids and discontinuities not acceptable Chemical Properties as per ISO 4422-2/11922-1 PVC-U Pipes F Chemicals Solvent Cement • 14 PVC-U Resin and additives Toxic additives like Cadmium and Mercury are only allowed in the amount of 0.9047 on “uPVC R/D Solvent Cement”.001 mg/lt (max) (see also WHO Recommendations) 1.1020 Kgf/mm² . Standard for testing methods: ISO-7381-1. and nondestructive test (5000 Newton) on all Footvalve assemblies Moulding Weight: Compare with reference weights Moulding Colour: Discoloration not desirable Moulding Surface Finish: Wrinkles. 250 ml in metal tins or tubes. BA70 & BA80 IS 8683 SKAT – RWSN Manual: Moulding Guidelines for Rubber Components ISO 1874-1 SKAT – RWSN Manual: Injection Moulding Manual for Afridev Handpumps ISO 9988-1 ISO 1163-1 ISO 1163-2 DIN 19532 DIN 7748-1 DIN 8061 DIN 8062 IS 4985 IS 12235 ISO-7387-1 ASTM D2-564 BS 5350-P.Material D Nitrile Rubber Chemical & Physical Properties Chemical Properties as per BS-2751 Compound No. BA70 & BA80 Acrilo Nitrile : 28% Mooney viscosity : 45 Physical Properties IRHD Hardness : 70 +5/-4 (BA 70) (Scale A) 80+5/–4 (BA 80) E Plastics Polyamide (PA 6. pitting not allowed. Packing should be sealed air-tight and opaque Equivalent Reverence Standards BS-2751 Compound No. Cements containing toulene and polysterene not to be used * 3.B2 Recommendations based on CRL’s report No. Cyclohex. Common solvents used :THF. MEK.B2 6. 2.A. Packing: Recommended size for use in the field. Polymer employed should not contain any plasticisers or any reground material * 4. pits. Recommended polymer content in solvent cements in 20-30% * 5. ASTM D2-564. October 1994 1 Mpa = 1 N/mm² = 0. surface finish to be smooth.

The quality control activities are performed by the manufacturer they can be divided into the following four stages: a) Procedure for Inspection of raw materials and bought out items b) Stage Inspection of components and sub-assemblies during production c) Final inspection and marking procedure The Internal Quality Control should have verifiable records of various activities like inspection of raw materials. For certain dimensions or configurations. it is segregated and the supplier needs to be informed immediately. To carry out some specific tests on certain assemblies like spin welding of valve bodies. a corrective action is required or the material is to be rejected totally. In some cases it is easy to check the dimensional conformity by using templates. The list of testing equipment is given in Annex V.1 General Checks Following general checks are required to be carried out for all incoming materials. special testing equipment is required. samples may be drawn and sent to an independent laboratory to check the conformity to specifications. This rejected material shall not be taken into stock. components and sub-assemblies at various stages of manufacture. A number of dimensional checks and performance tests need to be carried out during the various stages of Internal Quality Control. The list of measuring instruments and standard gauges are given in Annex II and Annex III. e) If material is not conforming. 2. To check dimensional conformance of raw materials. If there is a discrepancy in a certificate. concerned goods should be immediately segregated and reported to the manager in charge of production. c) Verification of test certificates furnished along with the material for conformity with standards. bought-out items. • Any deviation or corrective action taken needs to be recorded. b) Visual inspection is to be carried out for any damages and material defects. it may be necessary to use special gauges. a) Verification of quantity and completeness of delivery against purchase order. leakage and discharge test on cylinder assemblies. Templates do not give the exact dimension but indicates whether overall profile of a component is within permissible limits (tolerances). Templates are very useful for checking parts during production or when inspection is to be carried out on large number of components. measuring instruments and gauges are required. These tests are carried out before final assembly and clearance. measuring instruments. periodical checks on gauges. • In case. templates. A typical format of a rejection note (Deviation Report) is given in Annex I. all material concerned should be withdrawn from the factory premises. 15 . If a production inspector observes a deviation or non-conformance during inspection. 2.2 General Checks during Handpump Production Internal Quality Control is essential for achieving overall quality of the end product. The list of recommended templates and special gauges is given in Annex IV. d) Check dimensions as per specification drawings and record observations.3 Procedure for Inspection of Raw Materials & Bought Out Items Following procedures shall be followed for the inspection of raw materials & bought out items. components and assemblies at various stages of pump manufacture. The defect should then be analysed to ascertain whether a deviation can be allowed. jigs & fixtures etc.2. the correction is not possible.3.

grade of steel and date of production Dimensional checks as per purchase order and SKAT-RWSN drawings --- Brass bars Surface finish. blow holes. grade of steel and date of production Dimensional checks as per purchase order and SKAT-RWSN drawings Bend test. grade of brass and date of production Dimensional checks as per purchase order and SKAT-RWSN drawings --- c d e 16 . Magnet.3.1 Checks for Raw Materials and Bought Out Items The specific inspection checks to be carried out on raw materials and bought out items are given in Tables 2 and 3. transport damages Manufacture’s identification. porosity transport damages Manufacture’s identification. roughness. verification of markings. These checks are based on the nature of materials procured. lamination. Cupping test. Material Visual Checks (100%) Verification of Markings Dimensional Checks (10%) Physical and other Tests a Carbon and Stainless Steel: Hot rolled plates/bars Surface flaws.2. blow holes. lamination. transport damages Manufacture’s identification. of Stainless Steel Pipes Surface finish. pitting. blisters lamination. 2. grade of steel and date of production Dimensional checks as per purchase order and SKAT-RWSN drawings --- Bright bars Surface finish. These tables give details like the type of material. cracks. tube straightness. Magnet test for mat. grade of steel and date of production Dimensional checks as per purchase order and SKAT-RWSN drawings Brinell hardness.4. rust. cracks. rust scoring marks of production dies. important dimensional checks and other specific tests to be carried out for each pump type. visual checks.2 Specific Checks for Raw Materials and Bought Out Items Specific inspection checks on raw materials and bought out items are required for all materials used for manufacturing of any handpump type. rust. porosity transport damages Manufacture’s identification.test for materials of Stainless Steel b Carbon and Stainless Steel: Coldrolled sheets Flatness. transport damages Manufacture’s identification. Table 2 Specific Inspection Checks for Raw Materials No. Bend test.4 Specific Checks for Afridev Handpumps 2. Impact test. rust. of edges. imperfect edges.

scales Manufacture’s identification.5 mm Verify test certificate for material quality 1e Union nut C5892 Stainless St. Smooth surface. transport damage --- Ø48 +/-0.8 +0.175 Check for easy connecting of thread with footvalve body C2759 or C2761 3e Fishing connector C2220 Brass Check for cracks. date of production Dimensions as per SKAT-RWSN drawings Verify test certificate for material quality 3a Liner C2073 Brass Surface smoothness.2 mm Ø47 +0. Ø39.Table 3 Specific Inspection Checks for Bought Out Items No. dim. transport damages Grade of steel Ø50 +/-0. seams or scales.1 mm. transport damages Grade of steel Ø50 +/-0.2/0 mm.2 mm. transport damages --- Smooth surface finish of inside bore (0. Smooth surface.5 +0.0 0/-0. especially in the valve area (30°) --- Ø47 +/-0. coating.2 mm Ø47 +0. especially in the valve area (30°) --- Ø40. Smooth surface. Ø36 0/-0.2/0 mm Verify test certificate for material quality 1b Sleeve C2032 Stainless St. 10 +0. seams or scales.2 mm. cracks materials flaws.4μ) Test smoothness of inner bore diameter 3b Footvalve receiver C2299 Brass Check for dents in the conical part.2 mm Ø35 +/-0. transport damages Grade of steel Ø38 0/-0.1 mm.1/0 mm length 57. Ø44.2/0 mm Verify test certificate for material quality 1c Sleeve C2026 Stainless St.9 +/-0. Malformation of threads and smooth conical surface Grade of steel Dimensions as per SKAT-RWSN drawings Check for proper engagement with C5897 and C5893 2 Nuts. transport damage Manufacture’s identification.2/0 mm. 4. seams.2 mm length 119 0/-0.1/0 mm Check for proper engagement with Footvalve body C2759 or C2761 3c Footvalve bodyC2759 or C2761 Brass Check for cracks. valve seat 30° +/-30’ thread Rd30 x 3. sharp edges.0 +/-0.3 +0.1/0 mm length 109 +0. grade of material. Part name Visual Checks (100%) Verification of Markings Dimensional Checks (10%) Physical and other Tests 1 Pumprods (Mild Steel & Stainless St. transport damages Grade of steel Ø38 0/-0. bolts. valve seat 30° +/-30’ thread Rd30 x 3. coating. transport damage Manufacture’s identification and grade of steel Dimensions as per SKAT-RWSN drawings and / or purchase order Check for easy connection of threads 3 Brass components General Cracks. elongation and hardness. grade of steel and date of production Dimensional checks as per purchase order & SKAT-RWSN drawings Tensile.175 Check for easy connecting of thread with plunger body C2757 17 --- . bend.2 mm length 68 0/-0.175 Check for easy connecting of thread with Plunger body C2757 3d Plunger body C2757 Brass Check for cracks. seams or scales Thread Rd30 x 3.1 theoretical. dim. Ø49. Check with magnet for non-magnetic 1a Sleeve C2019 Stainless St.6 0/-0. pins and washers (MS and SS) Malformation of threads.1 mm and angle of 7° +/-15’. Smooth surface.) Damages.2 mm Ø35 +/-0. dim.1 mm. 3.5 mm Verify test certificate for material quality 1d Sleeve C2035 Stainless St.

8 +/-0. seams or scales 3g Collet C5893 Brass Check for cracks. B2085 spin welded Polyacetal Alignment of spinwelded components 4c Footvalve receiver C2074 Polyacetal Mould formation. grade of plastic and date of production Dimensions as per SKAT-RWSN drawings Test material grade.2 +0.3 +0. 28.2 mm 4. surface colour uniformity 4b Valve body assy. (3500 N).No.7 +/-0. surface colour uniformity Manufacture’s identification.2 +0.5+/-0.1 mm Ø42.2/0 mm Tensile test of spin welded parts. Ø33 +0.2 mm.3/0 mm --- .1 mm 30 +/-0. surface finish.2 mm 1. chamfer 18 Manufacture’s identification.2 mm Ø75 +0. seams or scales 3i Washer C1069 Brass 3j Hex. grade of plastic & date of production --- Ø63. surface colour uniformity 5a Bearing bush inner C2045 Polyamide Mould formation. L = 35.2/0 mm 6 0/-0.1 mm. sharp edges Manufacture’s identification and grade of material Dimensions as per SKAT-RWSN drawings Check for easy connection of threads 4 POM Plastic injectionmoulded components Mould formation. surface finish. surface finish.2/0 mm Check proper engagement with bearing bush outer C2044 Dimensions as per SKAT-RWSN drawings Test material grade. nut C1130 Brass Malformation of threads. Refer to SKATRWSN Injection Moulding Guidelines --- Ø46.2 mm Check proper engagement with bearing bush inner C2045 --- Check dimension of O-ring groove Ø29. surface finish.1 mm and O-ring groove Engagement test of footvalve assy.1/0 mm.2/0 mm Ø60. see SKAT-RWSN Injection Moulding Guidelines All Ø not possible to be checked (split).2 mm 2 +0.5 +/-0.2 +/-0. surface colour uniformity 6 PVC-U components General Smoothness of machined or moulded surface 6a Reducer C2080 PVC-U Smoothness of surface. A2096 or A2265 Dimensions as per SKAT-RWSN drawings Test material grade. surface finish. --- Ø49 0/-0. grade of plastic & date of production --- Manufacture’s identification. 3. see SKAT-RWSN Injection Moulding Guidelines --- 4a Bearing bush outer C2044 Polyacetal Mould formation. Part name Visual Checks (100%) Verification of Markings Dimensional Checks (10%) Physical and other Tests --- Dimensions as per SKAT-RWSN drawings Check for proper engagement of thread with union nut C5892 --- Dimensions as per SKAT-RWSN drawings Check proper fitment of cone with union nut C5892 --- Dimensions as per SKAT-RWSN drawings Check proper engagement of thread with union nut C5892 --- Dimensions as per SKAT-RWSN drawings --- 3f Connector C5897 Brass Check for cracks.3 0/-0. surface colour uniformity 5 PA Plastics injectionmoulded components Mould formation. seams or scales 3h Connector C5891 Brass Check for cracks.6 0/-0.

4.3. wall thick. transport damage Manufacturer’s identification.7 +0. no grooves.3/0 mm..3 mm Ø61.6 +0. 4. 4.5 0/-0.3.8/0 mm L = 850 +/-10 mm --- 7b Suction pipe C2081 PVC-U --- Serie 10.6 mm Ø13 +/-0. 5. Refer to SKATRWSN. PN 10 Ø75.5 mm 50 – 70 Shore A 9b Gasket C2059 Nitrile rubber --- --- 300/300 +/-2.9/0 mm L = 80 +/-2 mm --- 7i Top sleeve C2042 PVC-U 8 Solvent Cement for PVC-U 9 NBR Rubber components General 9a Flapper C2043 Nitrile rubber --- --- Ø80 +/-1. brand name and expiry date Manufacture’s identification. Hardness testing .5 0/-0. wall thick. wall thick. 5.3.9/0 mm L = 200 +/-5 mm --- --- Serie 6.7 +0.3/0 mm.6 +0. inclusions. PN 10 Ø63 +0. PN 16 Ø63 +0.7 +0. porosity.6/0 mm L = 1000 +/-10 mm --- 7c Sleeve C2082 PVC-U --- --- Ø12 +0.7 +0. 3. PN 16 Ø63.3/0 mm length 63 mm --- --- 7f 7g 7h Riser pipe C2046 PVC-U Riser pipe C2129 PVC-U Socket C2261 PVC-U --- Serie 6. date of production Dimensional Checks (10%) Dimensions as per SKAT-RWSN drawings and / or purchase order Physical and other Tests Verify test certificates for Impact test and Pressure test 7a Cylinder pipe C2072 PVC-U --- Serie 6. squareness of endfaces.8/0 mm L = 2900 +/-25 mm --- Serie 6.5 +/-0. wall thick. wall thick. grade of rubber & date of production Verify size of bottle or tube as ordered Dimensions as per SKAT-RWSN drawings Certificate of conformance as per order Verify test certificates. 4.No.5 mm Ø230 +/-1 mm 60 – 70 Shore A 9c Compression cone C2095 Nitrile rubber --- --- Ø120 +/-1.6 +0.5 mm dist.8/0 mm L = 3000 +/-25 mm --- --- Serie 6.3.3/0 mm. voids.3/0 mm. Part name 7 PVC-U extruded pipes General Visual Checks (100%) Verification of Markings Smoothness of surface. PN 16 Ø63.3.5 mm angle 30° 65 – 75 Shore A 19 Any damages and leakages Surface imperfections.2 mm.2 mm.2 mm Ø63 +0. wall thick. class and pressure rating of pipe. 260 +/-0. PN 16 Ø63.5 0/-0. PN 16 Ø63 +0. Moulding Guidelines for Rubber Parts.2 mm. flawmarks or faults Verify batch No. wall thick.8/0 mm L = 850 +/-10 mm --- 7e Sleeve C2263 PVC-U --- --- Ø12 +0. chamfers.3 0/-0.3/0 mm length 75 mm --- 7d Suction pipe C2262 PVC-U --- Serie 10.

5 mm Ø2. grade & type of polyester resin and date of production Dimensions as per SKAT-RWSN drawings Verify test certificates for pultruded polyester material with 60 to 70% glass fibre reinforcement 10a FRP Pumprod C5894 --- --- Ø10 +/-0.15 mm 65 – 75 Shore A 10 Polyester components General Surface imperfections.15 mm 65 – 75 Shore A 9n O-Ring C1021 Nitrile rubber --- --- ID Ø28 +/-3. If the manufacturer’s certificate is not available a sample may be drawn and checked for physical. chemical and other properties as per relevant specification(s).3 mm 70 – 80 Shore A 9i Centraliser C2076 (6”) Nitrile rubber --- --- ID Ø62.5 mm OD Ø100 +/-1 mm 70 – 80 Shore A 9h Centraliser C2077 (5”) Nitrile rubber --- --- ID Ø62.5 +/-0.5/-0.5 mm 70 – 80 Shore A 9e Centraliser C2109 Nitrile rubber --- --- Ø48 +/-1 mm slot 9. transport damage Manufacture’s identification.4 mm Ø3 +/-0.15 mm 65 – 75 Shore A 9m O-Ring C1020 Nitrile rubber --- --- ID Ø44.1 mm length 3000 +10/0 mm --- Note : Physical and chemical test certificates to be obtained from the manufacturer.5 mm OD Ø118 +/-1.35 mm Ø18 +/-0.5 +/-0.5”) Nitrile rubber --- --- ID Ø62.5 mm OD Ø92 +/-1 mm 70 – 80 Shore A 9g Centraliser C2078 (4.2 +/-0.5 +/-0.5 +/-0.5 mm OD Ø140 +/-1.4 mm 80 – 90 Shore A 9l O-Ring C1011 Nitrile rubber --- --- ID Ø39 +/-0.3 mm 70 – 80 Shore A 9j Bobbin C2088 Nitrile rubber --- --- Ø26 +/-0.6 mm Ø36 +0. flawmarks or faults.2/-0.5/0 mm length 30 +/-1 mm 70 – 80 Shore A 9f Centraliser C2079 (4”) Nitrile rubber --- --- ID Ø62. 20 .2 mm 10 0/-0.35 mm Ø4 +/-0.5 +/-0.25 mm length 44 +/-1 mm angle 30° +/-30’ 70 – 80 Shore A 9k Cup seal C2758 Nitrile rubber --- --- Ø50 +0.No.5 +0. Part name Visual Checks (100%) Verification of Markings Dimensional Checks (10%) Physical and other Tests 9d Centraliser C2212 Nitrile rubber --- --- Ø48 +/-1 mm Ø16 +/-0.

If the components are found in conformance with the drawings. 2. 2 x 150 +/-1. Annex VII & Annex VIII. position of holes Ø100 mm. and Process Stage Checks to be carried out Bracket plate C2007 Slot 16.2 mm. However. which will ensure interchangeability of components during assembly.5/0 mm. The sampling plan can vary depending on the condition of tooling and skills of the operators.2 +0. angle 15º and countersunk 60° Stopper plate C2008 Squareness of sides & dim.2 +0. Unless a component or assembly is accepted in the stage inspection it shall not be moved to the next stage for further processing. production can continue. Ø18 mm. Components produced with punches. If the “Ist” batch of 10 pieces is satisfactory. An indicative sampling plan could be as follows: “Ist” batch of 10 pieces at the start of the shift or whenever the tooling/operator is changed. jigs and fixtures. Locate all components of Stage 1 in fixture Proper orientation of all items (correct position of 15° angle) as per drawing B2006 Stage 3 Tack welding Dimension 43 +/-0.5 mm (86 mm) Stage 4 Full welding Weld quality (only outside).2 mm with slot gauge E0010. if any. These check lists can be converted into production documents and used for inspection by the manufacturer. To ensure repetitive accuracy in mass produced components and assemblies. Deviations. The production should be stopped whenever the deviations are beyond acceptable limits. An indicative list of recommended fixtures and tools are given in Annex VI.2. position of slot 16.3 Checks on Components and Sub-assemblies The Tables 4 to 39 below give details of checks to be carried out on components and assemblies at various stages of production.5. slot 20 +/-1 mm and total length 460 +/-3 mm Stage 1 Stage 5 21 Remarks .4. Table 4 Pump head assembly B2003 Inspection Stage Drawing No. Ø25 mm. the first few components or a small batch shall be checked for correct dimensions as per drawings. dies.4. dimension 135 0/-1 mm. dimension 120. Locate all components of Stage 5 in fixture Orientation of all items as per drawing B2047 Stage 7 Tack welding Angle 90° of Spout end Stage 8 Full welding Weld quality Stage 9 Body (channel) C2004 Channel squareness. Corrective action should be taken to rectify the process before starting the production again. 2 +0.. angle 45° and cut-out dimension 44 +1/0 mm (check orientation) Spout end C2011 Dimensions as per drawing Stage 6 preparing of spout assy. should be noted in the observation column (Remarks).5 +/-0. 120. etc.2 Stage Inspection during Production In order to have effective control on quality.5/0 mm with distance gauge E0009 Spout C2010 Length 300 or 580 mm. These checks are generally carried out on a sample basis.3/0 mm Stage 2 preparing of bracket assy. it is economical to use special work holding and tool guiding devices. stage inspections are required to be carried out on components and assemblies. 10% of the production batch needs to be checked at random at each stage of operation. These devices will help in producing components with consistent dimensional accuracy. Ø50 mm. bulk production can be taken up.

length 109.2 +0.2+0.5 mm.4 +0. 1 mm (compared to template) Overflow cover C2009 Dimensions as per drawing Stage 10 preparing of pump head Locate all components of Stage 9 and all other assemblies in fixture Orientation of all components and assemblies as per drawing B2003 Stage 11 Tack weld all items including hex.5+/-0.5 +0.2 mm and chamfer 15° (E0010) Fulcrum housing C2016 Ø50. nut M16) Position of holes Ø13/18 mm Stage 4 Full welding Weld quality.5 +1/0 mm Handle pipe C2018 Length 585 +/-3 mm. nut M16 for fixing of cover Flange butting to spout assembly.5 +/-0.5/0 mm and 16. & Process Stage Checks to be carried out Stage 1 Handle fork left C2014 Dimension 187. (140/180 +/-0.5 mm unevenness max.1 mm. orientation of holes Ø18 and Ø13 mm with radius R38 +1/0 mm Stage 2 preparing of handle front Locate all components of Stage 1 in fixture Orientation of all items in fixture as per drawing B2013 and check position of handle forks Stage 3 Tack weld all items (incl.5 mm.1/0 of sleeve with plug gauge E0015 Stage 7 Milling of slots Slots 6. dimension 288 +/-2 mm. sleeve should not protrude on either side. R38 +1/0 mm. alignment of handle pipe with handle forks on fulcrum housing Stage 5 Galvanizing Galvanization and passivation.5/0 mm with Distance gauge E0027 and check Ø50. correct position of fulcrum bracket.2/-0. 466 +/-4 mm. 135 0/-1 mm and 140 +/-2 mm Stage 13 Galvanizing Galvanization and passivation.5 +/-0.5 mm) with template E0026 & centre hole Ø78 +/-0. 120. check orientation of slots 22 Remarks Remarks . R38 +1/0 mm.2 mm and depth 7.5 +/-0.5/0 mm.3 +/-0. Check Ø47 +0.5 mm. check dimensions after galvanizing 69. dimension of fulcrum plates and slots after galvanizing. slot 16.2/-0.2/0 mm Spacer C2017 Dimension 68. position of overflow cover.5 +/-0.2 mm and chamfer 15° (E0010) Handle fork right C2015 Dimension 187.Inspection Stage Drawing No.1 mm Stage 6 Fitting of sleeve C2019 Check tightness of sleeve in fulcrum housing. squareness of body to flange 90° +/-1° Stage 12 Full welding Weld quality.2 mm (E0009/10) Table 5 Handle front assembly B2013 Inspection Stage Drawing No. slot 16. centre distance 70 and 90 mm.4 +0. hex. and Process Stage Checks to be carried out Flange C2005 Holes for Ø14 +/-0.5 +0.

2/-0.4 +0. check tightness. sleeve should not protrude on either side.5 mm Hex.5/0 mm.5 mm max. holes Ø33 +/-0. check inner dia. nut special C2027 Dimensions as per drawing Pin C1027 Dimensions as per drawing Washer C1028 Dimensions as per drawing Fitting of sleeve.7 0/-0. check dimension 58.1 mm and length 58 +0.2 mm and depth 7. of sleeve with plug gauge E0015 23 Remarks Remarks .2/0 mm Connector C2030 Orientation of thread M16 to R 31 +/. check outer dia.2 mm.5 mm. Ø38 0/-0. Ø6 +0. length 400 +/-5 mm Stage 2 Tack welding Centricity of T-bar (200 mm either side) Stage 3 Full welding Weld quality Stage 4 Galvanizing Galvanization and passivation Table 7 Fulcrum pin assembly B2024 Inspection Stage Drawing No. of sleeve with ring gauge E0014. 13 +/-0.5 mm with snap gauge E0011 Stage 2 Electroplating Check electroplating Sleeve C2026 Ø35 +/-0. & Process Stage Checks to be carried out Stage 1 Fulcrum pin C2025 Ø34.2/0 mm Retainer bush C2031 Dimensions as per drawing Stage 2 Locating in fixture Orientation of all items as per drawing B2028 Stage 3 Tack welding Centricity of connector and retainer bush Stage 4 Full welding Weld quality Stage 5 Galvanizing Galvanization and passivation. check dim.3 +/-0.5 +0. T-Bar C2022 Ø32 +/-0. check riveting Stage 3 Table 8 Remarks Rodhanger assembly B2028 Inspection Stage Drawing No. and Ø50. slot 6.2/0 mm Stage 6 Fitting of Sleeve and milling of slots Check tightness of sleeve.6. pins Ø6 mm protruding 4 +0.Table 6 Handle rear assembly B2020 Inspection Stage Drawing No.2 mm and length 119 0/-0.4 +0.2 mm. assembling of all items of Stage 2 and rivet pin ends Sleeve shall not protrude from pin.5 +0.0.5/0 mm.5 mm and hole Ø12.02/0 and length 120 0/-0. dim. 12 mm with gap gauge E0013. & Process Stage Checks to be carried out Stage 1 Extension pipe C2021 Length 615 +/-5 mm. & Process Stage Checks to be carried out Stage 1 Hanger bush C2029 Ø50.2 mm.

5 mm Hex.2 mm. slot 32 mm.2 mm. check centre distance 140/180 +/. 215 mm after bending.5/0 mm. & Process Stage Checks to be carried out Stage 1 Stand pipe C2051 Length 690 +/-3 mm and existence of hole Ø8 mm Flange C2053 Holes for Ø14 +/-0. angle 40° and 22°. length 337 mm Deflector C2040 Dimensions as per drawing Shroud C2041 Dimension 35 mm (after rolling) Stage 2 Locate all items of Stage 1 in fixture Orientation as per drawing B2036 Stage 3 Tack weld all items Centricity of deflector and shrouds Stage 4 Full welding Check weld quality and easy fixing & removal of cover on pump head Stage 5 Galvanizing Galvanization and passivation Remarks Table 11 Stand assembly B2050 Inspection Stage Drawing No. slot 32 mm. check dim.Table 9 Hanger pin assembly B2033 Inspection Stage Drawing No.5 mm with template E0026 and centre hole Ø166. Ø38 0/-0. 13 +/-0. check riveting Stage 3 Remarks Table 10 Cover assembly B2036 Inspection Stage Drawing No. dim.7 0/-0.2 mm and length 68 0/-0. dim. pins Ø6 mm protruding 4 +0. check outer dia. & Process Stage Checks to be carried out Stage 1 Cover plate C2037 Length 575 +/-2 mm.5 +/-0. dim. & Process Stage Checks to be carried out Stage 1 Hanger pin C2034 Ø34. assembling of all items of Stage 2 and rivet pin ends Sleeve shall not protrude from pin.5 mm with snap gauge E0012 Stage 2 Electroplating Check electroplating Sleeve C2035 Ø35 +/-0. Ø6 +0. check tightness. length 337 mm Right side plate C2039 Hole Ø40 mm. slots 18 mm and 65 mm Left side plate C2038 Hole Ø40 mm. angle 40° and 22°.5 mm. nut C1018 Dimensions as per drawing Pin C1027 Dimensions as per drawing Washer C1028 Dimensions as per drawing Fitting of sleeve.0. 12 mm with gap gauge E0013. of sleeve with ring gauge E0014. 215 mm after bending.5 mm Leg C2054 Dimensions as per drawing Gusset C2052 Dimensions as per drawing Stage 2 Locate all items of Stage 1 in fixture Orientation of components as per drawing B2050 Stage 3 Tack welding Dimension 965 +/-5 mm and position of legs (80°) 24 Remarks .2 mm.02/0 and length 69 0/-0.

centre hole Ø180 +/-0.5 mm.5 mm Gusset C2052 Dimensions as per drawing Gusset C2058 Dimensions as per drawing Stage 2 Locate all items of Stage 1 in fixture Orientation of components as per drawing B2221 Stage 3 Tack welding Dimension 540 +/-5 mm Stage 4 Full welding Weld quality Stage 5 Galvanizing Galvanization and passivation Remarks Table 13 Anchor assembly B2083 Inspection Stage Drawing No.0. check centre distance 260 +/-0. & Process Stage Checks to be carried out Stage 4 Full welding Weld quality Stage 5 Galvanizing Galvanization and passivation Remarks Table 12 Stand assembly B2221 Inspection Stage Drawing No.5 mm.5 +/-0.2 mm and angle 60° Eye C2094 Dimension as per drawing Stage 2 Tack welding Orientation of eyes as per drawing B2092 Stage 3 Full welding Weld quality Stage 4 Galvanizing Galvanization and passivation 25 Remarks . check centre distance 140/180 +/.0.5 mm Bottom flange C2068 Plate size 300 +/-2 mm.5 mm. check centre distance 140/180 +/. holes Ø18 +/-0.Inspection Stage Drawing No. & Process Stage Checks to be carried out Stage 1 Fixing rods C2084 Dimensions as per drawing Hex.5 mm) with template E0026 and centre hole Ø166.5 mm. & Process Stage Checks to be carried out Stage 1 Stand pipe C2056 Length 526 +/-3 mm and existence of hole Ø8 mm Flange C2053 Holes for Ø14 +/-0. Ø76 +/.5 mm with template E0026. bolts C1114 Dimensions as per drawing Stage 2 Locate all items of Stage 1 in fixture Orientation of components as per drawing B2083 Stage 3 Tack welding Centre distance of bolts 260 +/-0. & Process Stage Checks to be carried out Stage 1 Steel cone C2093 Holes Ø14 +/-0.5 mm Stage 4 Full welding Weld quality Stage 5 Galvanizing Galvanization and passivation Remarks Table 14 Steel cone assembly B2092 Inspection Stage Drawing No.

5 0/-0. & Process Stage Checks to be carried out Stage 1 Cylinder pipe C2072 Length 850 +/-10 mm and chamfer 15° as per drawing Liner C2073 Length 700 +/-2 mm and chamfer 15° on inner dia.3 mm. hole Ø12 +0.5 mm Stage 4 Gluing sleeve C2082 & reducer C2080 in suction pipe C2081 Check for correct positioning Stage 5 Assembling items of Stage 2. dents and bulges. straightness of cylinder. no scratches or damages Shrink fit of liner in cylinder pipe and machining of lower section Tightness of fitment. Ø75. hole Ø61. 3 and 4 Check for tightness and correct positioning as per drawing B2071 Stage 2 Stage 3 Remarks Table 17 Cylinder assembly B2279 Inspection Stage Drawing No. surface finish inside bore must be smooth. check O-ring groove with snap gauge E0020 Assemble footvalve receiver with O-ring C1020 Check for correct fitness of O-ring Reducer C2080 Outside Ø75 +0.3 0/-0. surface finish inside bore must be smooth.2 mm and length 135 0/-3 mm Suction pipe C2081 Bell-end dia.2/0 mm and length 110 +5/0 mm Footvalve receiver C2074 Dimensions as per drawing.2 mm. & Process Stage Checks to be carried out a Gasket C2059 Check centre distance 260/260 mm and centre hole Ø230 +2/0 mm b Compression cone C2095 Ø120 +/-1. height 31 +/-1 mm and angle 30° c Bearing bush outer C2044 Dimensions as per drawing d Bearing bush inner C2045 Dimensions as per drawing Remarks Table 16 Cylinder assembly B2071 Inspection Stage Drawing No. no scratches or damages 26 Remarks . dents and bulges.3/0 mm. of liner with plug gauge E0016.5/0 mm on position 250 +/-10 mm and length of 1000 +/-10 mm Sleeve C2082 Outside Ø12 +0.. check inner dia..Table 15 Other above ground components Inspection Stage Drawing No.5 mm.3/0 mm and length 75 +/-0. machined length to be Ø63 +0. with chamfer 15°. inside Ø63. & Process Stage Checks to be carried out Stage 1 Cylinder pipe C2072 Length 850 +/-10 mm and chamfer 15° as per drawing Liner C2073 Length 700 +/-2 mm and chamfer 15° on inner dia.5 +/-0.

inside and outside chamfers 15° and length 2900 +/-25 mm b Top sleeve C2042 Inner Ø63.5 +/-0.3/0 mm and length 63 +/-0.5 mm.5/0 mm on position 250 +/-10 mm.5 +/-0. straightness of cylinder.3 mm and thickness of 24 +/-1 mm Centraliser 5” C2077 Hole Ø62. inside and outside chamfers 15°.5 mm. outside Ø92 +/-1 mm and thickness of 24 +/-1 mm Remarks . length 850 +/-10 mm and hole Ø12 +0.5 0/-0.3 mm and thickness of 24 +/-1 mm e Centraliser 4. machined length to be Ø63 +0.2/0 mm and length 110 +5/0 mm Footvalve receiver C2299 Dimensions as per drawing.3/0 mm.5 0/-0.2 mm.1.1. 3 and 4 Check for tightness and correct positioning as per drawing B2297 Stage 3 Remarks Rising main assemblies A2099 and A2119 Table 18 Rising main components Inspection Stage 27 Drawing No. outside Ø140 +/. of liner with plug gauge E0016.5” C2078 Hole Ø62. inside chamfers 15° and length 80 +/-2 mm c Flapper C2043 Dimensions as per drawing Centraliser 6” C2076 Hole Ø62.5 mm. bell-end Ø63. & Process Stage Checks to be carried out a Riser pipe C2046 Outer Ø63 +0.5 mm.30/-0.5 +/-0. inside chamfers 15° and length 200 +/-5 mm Stage 4 Gluing sleeve C2263 & socket C2261 to suction pipe C2262 Check for correct positioning Stage 5 Assembling items of Stage 2. & Process Stage Checks to be carried out Stage 2 Shrink fit of liner in cylinder pipe and machining of lower section Tightness of fitment. check O-ring groove with snap gauge E0020 Assemble footvalve receiver with O-ring C1020 Check for correct fitness of O-ring Suction pipe C2262 Outside Ø63 +0.5 +/-0.2 mm. check inner dia.3/0 mm.Inspection Stage Drawing No.5 mm Socket C2261 Inside Ø63. pipe length 850 +/-10 mm Sleeve C2263 Outside Ø12 +0.1 mm and thickness of 24 +/-1 mm f Centraliser 4” C2079 Hole Ø62.2 mm. outside Ø118 +/. outside Ø100 +/.

25 mm and valve seat 30° +/-30’ without sharp edges O-ring C1021 Dimensions as per drawing Hex.2 mm.2 +0.2/0 mm.6 mm. dimension 10 0/-0.2/0 mm.25 mm and valve seat 30° +/-30’ without sharp edges Assembling all items of Stage 1 Fitment of cup seal C2758 and check easy play of bobbin C2088 Stage 2 Table 21 Footvalve arrangement A2096 Drawing No. & Process Stage Checks to be carried out Stage 1 Valve body lower C2086 Dimensions as per drawing Valve body upper C2087 Dimensions as per drawing Stage 2 Spin welding of Valve body parts Check weld with tensile testing machine at 3500 and 5000 Newton Stage 3 Machining of O-Ring groove Ø29.3/0 mm. 10 +0.2 +/. Ø36 +05/-0. Ø36 0/-0. valve seat 30° +/-30’ and Rd 30 x 3. & Process Stage Checks to be carried out Stage 1 Riser pipe C2129 Outer Ø63 +0. check O-ring groove with snap gauge E0022 Eye assembly B2089 Dimensions as per drawing Bobbin C2088 Ø26 +/-0.0.35 mm. bolt C1066 Dimensions as per drawing Washer C1064 Dimensions as per drawing Assembling all items of Stage 2 and 3 Fitment of O-ring.175 mm. easy play of bobbin and proper locating of footvalve arrangement A2096 in footvalve receiver C2074 28 Remarks Polyacetal with Eye connector (Stainless Steel) Inspection Stage Stage 4 Remarks Remarks .Table 19 Riser pipe assembly B2106 Inspection Stage Drawing No.2/-0. Ø18 +/-0.35 mm. 3.5 0/-0. inside chamfers 15° and length 200 +/-5 mm Gluing sleeve C2261 to riser pipe C2129 Check for tightness and correct positioning as per drawing B2106 Stage 2 Table 20 Plunger assembly A2266 (Brass plunger with Rubber seal) Inspection Stage Drawing No.2 mm. check cup seal groove with gauge E0040 Cup seal C2758 Ø50 +0.1 mm and dim.2 mm. inside and outside chamfers 15°. length 3000 +/-25 mm Socket C2261 Inner Ø63.4 mm Bobbin C2088 Ø26 +/-0. Ø18 +/-0. & Process Stage Checks to be carried out Stage 1 Plunger body C2757 Ø47 0/-1 mm.

Ø18 +/-0. proper locating of footvalve arrangement A2265 in footvalve receiver C2074 Stage 4 Table 23 Footvalve assembly A2298 (Brass) Inspection Stage Drawing No. correct fitment of push rod. nut C1121 Dimensions as per drawing Assembling all items of Stage 1 Fitment of O-ring. easy play of bobbin.35 mm. bolt C1120 Dimensions as per drawing Hex. & Process Stage Checks to be carried out Stage 1 Valve body assembly B2085 Dimensions as per drawing Fishing connector C2220 Check threads Rd 30 x 3. Check O-ring groove with snap gauge E0039 Bobbin C2088 Ø26 +/-0.Table 22 Footvalve arrangement A2265 Polyacetal with threaded Fishing connector (Brass) Inspection Stage Drawing No. Mild Steel (only Top rod & Pumprod) Table 25 Top rod assembly B2207 Inspection Stage Drawing No. correct fitment of hex. easy play of bobbin. M10 and M6 Bobbin C2088 Ø26 +/-0.35 mm. & Process Stage Checks to be carried out Stage 1 Eye C2090 Dimensions as per drawing Connector C2091 Dimensions as per drawing Full welding Weld quality Stage 2 Pumprod arrangement A2206 Remarks threaded. Ø18 +/-0.25 mm and valve seat 30° +/-30’ without sharp edges O-ring C1011 Dimensions as per drawing Hex. bolt C1066 Dimensions as per drawing Washer C1064 Dimensions as per drawing Assembling all items of Stage 2 and 3 Fitment of O-ring.2 mm Coupler C2213 Dimensions as per drawing 29 Remarks . bolt and nut and proper locating of footvalve assembly A2298 in receiver C2299 Stage 2 Remarks Remarks Table 24 Eye assembly B2089 Inspection Stage Drawing No. & Process Stage Checks to be carried out Stage 1 Rod C2208 Length 2990 +5/0 mm and Ø12 +/-0. & Process Stage Checks to be carried out Stage 1 Footvalve body C2759 or C2761 Dimensions as per drawings.175.25 mm and valve seat 30° +/-30’ without sharp edges Push rod C2760 Dimensions as per drawing O-ring C1021 Dimensions as per drawing Hex.

& Process Stage Checks to be carried out Stage 1 Rod C2372 Length 2990 +5/0 mm and Ø12 +/-0. coupler C1012 Dimensions as per drawing Stage 2 Tack welding Position of all items as per drawing B2214 Stage 3 Full welding Weld quality Stage 4 Galvanizing Galvanization and passivation. & Process Stage Checks to be carried out Stage 1 Rod C2211 Length 2990 +5/0 mm and Ø12 +/-0.2 mm Coupler C2213 Dimensions as per drawing Hex. Stainless Steel (all rods) Table 27 Top rod assembly B2210 Inspection Stage Drawing No.Inspection Stage Drawing No.2 mm Hex.2 mm Coupler C2215 Dimensions as per drawing Hex. & Process Stage Checks to be carried out Stage 2 Tack welding Position of items as per drawing B2207 Stage 3 Full welding Check weld quality Stage 4 Galvanizing Galvanization and passivation.2 mm Coupler C2215 Dimensions as per drawing Stage 2 Tack welding Orientation of items as per drawing B2210 Stage 3 Full welding Check weld quality and interchangeability of thread Remarks Table 28 Pumprod assembly B2216 Inspection Stage Drawing No. and check thread for interchangeability Remarks Table 26 Pumprod assembly B2214 Inspection Stage Drawing No. coupler C1053 Dimensions as per drawing Stage 2 Tack welding Orientation of items as per drawing B2216 Stage 3 Full welding Check weld quality and interchangeability of thread Remarks Table 29 Plunger rod assembly B2258 Inspection Stage Drawing No. & Process Stage Checks to be carried out Stage 1 Rod C2382 Length 2990 +5/0 mm and Ø12 +/-0. and check threads for interchangeability Remarks Pumprod arrangement A2209 threaded. & Process Stage Checks to be carried out Stage 1 Rod C2259 1000 +/-3 mm and Ø12 +/-0. couplers C1053 Dimensions as per drawing Stage 2 Tack welding Position of items as per drawing B2258 Stage 3 Full welding Check weld quality & interchangeability of threads 30 Remarks .

connecting thread M20. & Process Stage Checks to be carried out Stage 1 Rod C2113 Length 3000 +/-10 mm and Ø10 +/-0. & Process Stage Checks to be carried out a Connector C5897 Hole Ø10. & Process Stage Checks to be carried out Stage 1 Rod C2113 Length 3000 +/-10 mm and Ø10 +/-0.5 mm d Collet C5893 Ø14+0.2 mm Eye C2115 Dimensions as per drawing Connector C2118 Dimensions as per drawing Stage 2 Tack welding Position of items as per drawing B2116 Stage 3 Full welding Check weld quality & interchangeability of threads Remarks Pumprod arrangement A5889 Fibre Reinforced Plastic (FRP) Rods with connectors Table 33 Connector components for FRP Pumprods Inspection Stage 31 Drawing No. connecting thread M20 and length 45 +/-0.1/0 mm. angle 5° +/-15’.1/0 mm and length 23 +/-0. thread M12 and length 64 +/-1 mm c Union nut C5892 Ø14+/-0.2 mm Hook C2112 Dimensions as per drawing Stage 2 Tack welding Orientation of items as per drawing B2111 Stage 3 Full welding Check weld quality and interchangeability of thread Remarks Table 31 Pumprod assembly B2114 Inspection Stage Drawing No.1 +0. Stainless Steel (all rods) Table 30 Top rod assembly B2111 Inspection Stage Drawing No.5 mm b Connector C5891 Hole Ø10.Pumprod arrangement A2110 Hook & Eye.2/0.1. & Process Stage Checks to be carried out Stage 1 Rod C2117 Length 735 +/-5 mm and Ø10 +/-0. connecting thread M20 and length 70 +/-0.1 +0. outer Ø17 0/-0.1/0 mm.2 mm Remarks .2 mm.2 mm Hook C2112 Dimensions as per drawing Eye C2115 Dimensions as per drawing Stage 2 Tack welding Orientation of items as per drawing B2114 Stage 3 Full welding Check weld quality and interchangeability of thread Remarks Table 32 Plunger rod assembly B2116 Inspection Stage Drawing No. inner Ø10 +0. angle 5° +/-15’.

length 30 +/-1 mm c FRP Rod C5894 Ø10 +/-0.1 mm and length 70 +/-1 mm Stage 2 Full welding Weld quality Stage 3 Electroplating Electroplating Remarks Table 36 Resting tool assembly B2415 Inspection Stage Drawing No.2/0 mm Stage 4 Full welding Weld quality Remarks Table 37 Connecting tool assembly B2420 Inspection Stage Drawing No.5 mm Limiter C2417 Dimensions as per drawing Handle C2413 Dimensions as per drawing Stage 2 Locate in fixture Orientation of all items as per drawing B2415 Stage 3 Tack welding Distance of limiters 19 +0.2 mm and length 200 +/10 mm T-bar C2422 Ø12 +/-0. centre distance 70 and 90 mm. slot 9.5 mm. & Process Stage Checks to be carried out a Centraliser C2212 Ø48 +/-1 mm and Ø16 +/-0.Table 34 Other Pumprod components Inspection Stage Drawing No.5 +0. & Process Stage Checks to be carried out Stage 1 Handle rod C2161 Ø16 +/-0.5 mm) check with template E0026 & slot 13 +/-0. (140/180 +/-0. & Process Stage Checks to be carried out Stage 1 Rod C2421 Ø12 +/-0.2 +/-0. & Process Stage Checks to be carried out Stage 1 Rod C2098 Length 1500 +/-5 mm and Ø12 +/-0.1 mm and length 3000 +10/0 mm Remarks Tools for Installation and Maintenance Table 35 Spanner assembly B2160 Inspection Stage Drawing No.2 mm and length 200 +/-10 mm Full welding of all items of Stage 1 Orientation of all items as per drawing B2420 and weld quality Stage 2 Table 38 Fishing tool assembly B2097 (for connecting with threaded pumprods) Inspection Stage Drawing No. coupler C1012 Dimensions as per drawing Cover plate C2151 Dimensions as per drawing 32 Remarks Remarks .5/0.2 mm and length 300 +/-5 mm Socket C2162 A/F 24. & Process Stage Checks to be carried out Stage 1 Flange C2416 Holes for Ø14 +/-0.2 mm Hex.5 mm b Centraliser C2109 Ø48 +/-1 mm.

The subassemblies of Afridev Handpumps are then assembled together to form main-assemblies. check function of fishing tool by inserting into assembled cylinder. & Process Stage Checks to be carried out Stage 1 Rod C2103 Length 2780 +/-10 mm and Ø10 +/-0. The list of general checks and specific checks to be carried out on assemblies are given below: 2. fishing hook should engage properly to be able to retrieve footvalve arrangement A2096 Stage 6 Table 39 Fishing tool assembly B2150 (for connecting with Hook & Eye pumprods) Inspection Stage Drawing No. fillet size. lumps. & Process Stage Checks to be carried out Side plate C2152 Dimensions as per drawing Back plate C2153 Dimensions as per drawing Stage 2 Locate in fixture Orientation of all items as per drawing B2097 Stage 3 Tack welding Check holes on side plates to be in line Stage 4 Full welding Welding quality Stage 5 Galvanizing Galvanization and passivation Fishing hook C2154 Dimensions as per drawing Pin C1029 Dimensions as per drawing Assembling items of Stage 5 for riveting Free movement of fishing hook in assembly. check function of fishing tool by inserting into assembled cylinder.1 General Checks The General Checks shall include the following: Welding: Check for blow holes. finish and positional accuracy. cracks. 33 . components are welded into sub-assemblies. pin holes. riveting of pin ends.5. distortion.2 mm Eye C2115 Dimensions as per drawing Cover plate C2151 Dimensions as per drawing Side plate C2152 Dimensions as per drawing Back plate C2153 Dimensions as per drawing Stage 2 Locate in fixture Orientation of all items as per drawing B2150 Stage 3 Tack welding Check holes on side plates to be in line Stage 4 Full welding Welding quality Stage 5 Galvanizing Galvanization and passivation Fishing hook C2154 Dimensions as per drawing Pin C1029 Dimensions as per drawing Assembling items of stage 5 for riveting Free movement of fishing hook in assembly. fishing hook should engage properly to be able to retrieve footvalve arrangement A2096 Stage 6 2. uniformity. discontinuity. undercuts. riveting of pin ends.Inspection Stage Drawing No.5 Remarks Remarks Inspection Check List for Main Assemblies After various stages of manufacture.

2+0. black spots.2 Specific Checks Table 40 Specific checks (assembly-wise) see detailed below: No. Description of Item Type of Checking b Handle assembly b1 Proper gluing of stainless steel sleeve in fulcrum housing and on fulcrum pin should be tight b2 The stainless steel sleeve should not protrude beyond the faces of fulcrum housing and fulcrum pin visual check b3 Free entry and proper locking of bearing bush outer in fulcrum housing slot to prevent rotation check location b4 Free entry of fulcrum pin in bearing bush inner should rotate freely b5 Check if bearing bush inner lug is located in the 16. Description of Item c Rodhanger assembly c1 Proper gluing of stainless steel sleeve in rodhanger assembly and on hanger pin assembly 34 Type of Checking should be tight . compared with template E0026 a6 Welding of M16 nut and bolt for fastening cover on pump head cover should not get detached without the use of the spanner No. nodules.2 +/-0. 40.5 mm with respect to gap between the handle forks right and left (69. 2.5 mm slot of the fulcrum bracket visual check b6 Alignment of slot 16.Hot Dip Galvanizing: Check for defects like flux. pits. Check coating thickness and uniformity of coating.5 mm) for proper seating of rodhanger assy. bulky white deposits. rust stains. ash. runs. blisters etc. Electroplating: Check for defects like blisters. cracks. burning or unplated areas. roughness. for easy and proper seating of the rodhanger assembly. check with slot gauge E0010. pimples.5.5/0 mm. Identification Mark: Check for manufacturer’s identification marks on components/subassemblies/main-assemblies as per Table No. pushed or pulled by hand fasten M16 bolt on handle rear and check for tightness No. check with slot gauge E0010 a2 Distance between fulcrum bracket plates 120.5 mm slots in fulcrum bracket and handle forks to be in line. bare patches. which are not permitted. use distance gauge E0027 b7 Free movement of handle rear inside the handle front insert handle rear and check for free movement in handle front b8 The effectiveness of locking the handle rear with M16 bolt – the handle rear should not get loose when T-bar is rotated. lumpiness. a5 Flatness of flange and position of holes unevenness maximal 1 mm. Check coating thickness and uniformity of coating. check with distance gauge E0009 a3 Squareness of body with respect to flange 90º +/-1º a4 Spout length 300 mm or 580 mm. Description of Item Type of Checking a Pump head assembly a1 Alignment of 16.

Description of Item g Rising main g1 ID of bell-ends and sockets to accommodate riser pipes 35 Type of Checking Ø63.5 mm slot of the handle forks visual check No. operation should not be tight f5 Tightness of centraliser on cylinder pipe should not be loose f6 Check moulding flashes on bobbin no flashes allowed No.No. Description of Item Type of Checking c2 Stainless steel sleeve should not protrude beyond the face of the rodhanger assembly and the hanger pin assembly visual check c3 Bearing bush outer should enter freely and get locked in the slots of the rodhanger assembly visual check c4 Hanger pin should enter freely in the bearing bush inner insert and check for free movement c5 Check if bearing bush lug is located in 16. check with trysquare and template E0026 e3 The position of the anchor bolts should be correct centre distance 260 +/-0.3 0/-0. Description of Item Type of Checking d Cover assembly d1 Check position of shrouds to be concentric with 18 mm slot at rear & Ø40 mm holes on the sides d2 Dimension of slot 32 mm d3 Dimension for opening of shroud 35 mm d4 Easy fixing and removal of cover must fit without use of force No.2 mm (for sockets) . Description of Item Type of Checking f Cylinder assemblies f1 Cylinder bore diameter 50 +0.3/0 mm.5 0/-0. (Type test at random at least 1% minimal) f3 Fitment of footvalve in footvalve receiver (with O-ring in position) visual check (for plastic and brass footvalve and footvalve receiver) f4 Full stroke movement of plunger (including cup seal) in cylinder pull and push to full stroke and observe the movement is proper. Description of Item Type of Checking e Stand assemblies e1 Overall height 965 +/-5 mm for stand B2050 and 540 +/-5 mm for stand B2221 e2 Flatness of flanges and correct location of holes to be within 1 mm.5 mm e4 The assembled compression cone should protrude the steel cone by 2 to 3 mm visual check No.2 mm (for bell-ends) and Ø63. plug gauge E0016 f2 Check slippage of sleeve in cylinder pipe (test load 400N) check on test rig.

No. Description of Item

Type of Checking

g2

Any offset of the bell end with respect to pipe

no offset permissible, bell-ends
must be concentric

g3

Length of riser pipe C2046 and length of riser pipe B2106

2900+/-25 mm and 3000+/-25 mm

g4

Outside diameter of centralisers Ø140, 118, 100 & 92 mm
depending on the casing pipe diameter

check as per purchase order

g5

Centraliser fitment on riser pipes

should not be loose

Note: Centralisers for riser pipes are only fitted shortly before pump installation takes place

No. Description of Item

Type of Checking

h

Pumprod arrangements

h1

Check threaded connectors for interchangeability

check thread by connecting them
with other pumprods

h2

Check Hook & Eye connectors for interchangeability

check hooks & eyes by connecting
them with other pumprods

h3

Fitment of pumprod centralisers on top rods & pumprods

fit on rod connectors and check

Note: Centralisers for pumprods are only fitted shortly before pump installation takes place

2.6

Final Inspection and Marking Procedure

2.6.1 Checks during Final Inspection
The final inspection of all pumps is to be carried out by the manufacturer. The checks to be carried
out are as follows:

Table 41

Final Inspection

No. Description

Type of Checking

1

Verify internal quality control reports which were made
during stage-wise inspection for components & assemblies
including manufacturer’s identification as given in Table 41

2

Completeness of all assemblies, components and fasteners,
Visual check
to be fully assembled

3

Check stroke length on each pump assembly

225 +/-6 mm

4

Flatness of flanges to provide proper matching, when they
are assembled one on top of each other

Gap not more than 2 mm, check with
feeler gauge

5

For the Leakage Test of the cylinders, the pressure of 1 and Check on test rig at minimum of 5%,
10 bar (on a hydraulic device) must be applied. (Please
of the consignment - no leakage is
note: without pressure, cylinders might be slightly leaking.) allowed

6

Proper engagement of footvalve in receiver

Visual and physical check

7

Movement of plunger within cylinder bore

Push and pull plunger assembly with
cup-seal to full stroke, no excessive
force required for moving the plunger

8

Easy and proper engagement of fishing equipment with
footvalve arrangement inside the cylinder

Engage and pull to retrieve the
footvalve assembly

9

Damages and other defects

Visual check

10

Check discharge on a test rig, cylinders drawn as per
sampling criteria specified in the Afridev Specification. At
random at least 5% minimal

Discharge not less than 16.5 litres of
water in 40 continuous full strokes in
one minute

36

Verify and record the observation

No. Description

Type of Checking

11

Check identification marks on parts

Identification marks

It is absolutely necessary to keep a record of final inspection findings.

2.6.2 Marking Procedure
The following is suggested for marking by the manufacturer on various pump parts:

Table 42

Identification Marks for Components and Assemblies

No.

Description

Type of Marking

1

Pump head

Year & month of manufacturing on name plate

2

Handle front assembly

Stamp identification mark on fulcrum housing

3

Rod hanger assembly

Stamp identification mark on hanger bush

4

Stand assemblies

Stamp identification mark on top flange

5

Top rod, pumprod and plunger rod

Stamp identification mark on pumprods

6

Cylinder assembly

Mark on outside, month & year of assembling

7

Plastic components

Mark on outside where possible

8

All PVC-U pipes

Mark on outside, year, month and batch No.

9

All rubber components

Identification mark placed where possible

37

3.0 External Quality Control (Quality Assurance)
3.1

Pre-Requisite for Quality Assurance
There are four pre-requisites to ensure supply of correct quality and quantity of handpumps in the
stipulated period. They are:
• Pre-qualification of suppliers
• Placement of a well defined purchase order
• Pre-delivery inspection at the manufacturers works
• End Inspection at the customer (see 4.0 End Inspection of delivered products on Page 52)

3.1.1 Pre-qualification of Pump Suppliers: Pre-qualification of bidders before inviting bids is
desirable. The pre-qualification of a handpump manufacturer will include evaluation of the
production facilities, organisational set-up, quality control set-up, inspection techniques, skilled
manpower, manufacturing tooling, jigs, fixtures, inspection gauges, instruments and test
equipment. The procedure for calibration and maintenance of gauges and instruments is also
evaluated. In general, it is an overall assessment of a manufacturer’s capability and capacity to
deliver goods conforming to specifications.
The pre-qualification inspection should be done by an experienced Independent Inspection
Agency (IIA). A format for evaluation of manufacturers with check-list and recommended points
weightage system is given in Annex X.
Only pre-qualified suppliers/manufacturers should be invited to bid. This procedure will keep the
“Ghost Suppliers” away and ensure supply of quality handpump within the stipulated time.

3.1.2 Clearly Defined Purchase Order: The purchase order plays an important role in getting the
correct materials. The purchase order should contain full details like specification of product,
quantity, pre-delivery inspection, supply conditions and commercial terms and conditions. Options
should be specified clearly like stand assembly options, length of spout, carbon steel or stainless
steel pumprods etc. An incomplete purchase order can result in delays and incorrect supplies. A
format for a purchase order with explanatory notes is found in Annex XI.

3.1.3 Pre-delivery Inspection: This is perhaps the most important part of the quality assurance
system. Experience shows that insistence on inspection of handpumps by an IIA creates a
psychological pressure and thereby forcing a manufacturer to take extra care during production.
Continued exposure to external inspection helps in improving overall quality of product. Although,
pre-delivery inspection at the manufacturer’s works costs extra money, such expenditure is more
than justified, keeping in view the advantages it offers.

It is therefore recommended, that all handpumps and spare parts are subjected to
pre-delivery inspection at the manufacturer’s works.

3.2

Procedure for Pre-delivery Inspection
On receipt of the copy of a purchase order, the Independent Inspection Agency (IIA) will work out
an inspection schedule in consultation with the manufacturer.
The manufacturer shall lay out the completed pumps systematically, assembly-wise for inspection
and provide the IIA with the relevant data pertaining to raw material, production and testing.
The test certificates provided by the manufacturer shall be verified against relevant specifications.
Checks will also be made to verify the effectiveness of the internal quality control system.
If the internal quality control is found satisfactory, the IIA shall proceed with 100% visual checking
of assemblies for workmanship and visual defects. If visual defects are found at this stage, the
manufacturer is allowed to replace the same defective assemblies.

38

Thereafter, random samples are selected as per the sampling plan for detailed check of attributes
and variables. The sampled assemblies are checked for the following.
1) Dimensional check (including checks with gauges, tools and instruments),
2) Visual check (welding, galvanizing and workmanship),
3) Interchangeability check (spare parts),
4) Performance check.
If the above checks are satisfactory, quantity check and inspector stamping and stencilling will
follow. If the above checks indicate defects beyond acceptable limit as per sampling plan, then the
total quantity is rejected.

3.2.1 Verification for the Effectiveness of the Internal Quality Control System
Verify Internal Quality Control (QC) System followed in the handpump manufacture for its
effectiveness with the following checks.
a) Incoming inspection records for quality of materials received including raw materials and
finished parts/components.
b) Verify the record of discrepancies noticed and measures taken to avoid recurrence.
c) When the manufacturing process is in progress, observe at random how the stage inspection
is carried out and findings are recorded.
d) Check if jigs, fixtures, testing apparatus, measuring instruments as gauges and templates are
used during manufacture and inspection tools are calibrated periodically.
e) Verify whether the complete set of instruments and equipment are available with the pump
manufacturer to carry out internal quality control checks.
f) Whether knowledge on quality control is imparted to the production and inspection staff and
periodical orientation and training of the staff is carried out.
g) Pick up some components and assemblies during stage inspection and audit them for quality
standards (with respect to QC Reports of internal QC-Department).
h) Verify whether the Internal Quality Control (IQC) personnel of the manufacturer have adequate
skills to carry out QC checks.

3.2.2 Sampling of Handpumps and Spare Parts for Pre-delivery Inspection
The objectives of sampling are twofold:
1) to make external inspection economical; and
2) to induce in the supplier psychological pressure of rejecting a Lot based on the nonconformity of the sample. This psychological pressure makes it imperative for the
manufacturer to take all steps to keep the internal quality control system effective.
When a specific value of Acceptable Quality Limit (AQL) is designated for certain nonconformities, it indicates that the sampling scheme will accept a Lot of handpumps, provided the
non-conforming samples Re (Rejection Number) does not exceed the Ac (Acceptance number).
Example:
For a batch of 500 pumps to be inspected with General Inspection Level I and AQL 1%, 20
handpumps are selected on random basis. The batch will be considered acceptable if all pumps in
the sample lot are found without any non-conformity.
If only one single pump out of the sampled pumps is found non-conforming, the whole lot of 500
handpumps shall be rejected.
As higher the inspection level, the more samples will be drawn. For instance:
If a batch of 500 pumps would be checked with a General Inspection Level III and AQL 1%, the
number of samples to be drawn would be 80 pumps.
Sampling plan for complete handpumps (Table 43) and sampling plan for handpump spares
(Table 44) is based on ISO 2859-1.
Sampling plans can be tightened or loosened depending on the past performance and reliability of
a manufacturer. Switching rules for normal, tightened or reduced inspections are given in ISO
2859-1.
39

c) Movement of plunger in cylinder (no excessive force shall be applied to move the plunger assembly). scratches and damages are not allowed.no leakage allowed.3. e) Outside diameter of the unlined cylinder portion. sampling can be done based on a tighter AQL level. 0 0 0 0 0 0 0 0 0 0 Note: In case the manufacturer has not been consistent in producing quality pumps.1 Checks for Important Attributes a) 100% interchangeability of sub-assemblies and spare parts. g) Footvalve leakage test at 1 bar and 10 bar hydraulic pressure . d) Engagement of fishing tool to the fitting of the footvalve assembly. The following specific checks are separately explained: • Checks for Important Attributes • Dimensional Check List • Performance Test • Inspection of PVC-U Riser pipes • Inspection and Marking Procedure 3. 40 . AQL 1%) Lot or Batch Size 2 8 9 15 16 25 26 50 51 90 91 150 151 280 281 500 501 1200 1201 and above Sample Size 2 2 3 5 5 8 13 20 32 50 Acceptance* No. check chamfer on either side of cylinder liner.3 Specific Checks for Afridev Handpumps 3. The decision for this shall be taken by the IIA inspector. AQL 1%) Lot or Batch Size 2 8 9 15 16 25 26 50 51 90 91 150 151 280 281 500 501 1200 1201 and above Sample Size 2 2 3 3 5 5 8 8 13 13 Acceptance* No. 0 0 0 0 0 0 0 0 0 1 Table 44 Recommended Sampling Plan for Handpump Spares (General Inspection Level S-3. b) Finish on inside diameter of cylinder liner. f) Tensile testing of valve body assembly.Table 43 Recommended Sampling Plan for Complete Handpumps (General Inspection Level I. Also check for engagement of footvalve in footvalve receiver.

5 +/-0. p) The fulcrum pin together with the handle assembly shall fit easily between the plates of the fulcrum bracket and into the 16.2 mm 69. black spots. The same also applies also to the fulcrum pin and hanger pin. blow holes.2/0 mm slots. The retainer bush must then be in line with the two slots provided at the top face of the pump head assembly. If the performance of the manufacturer is not consistent. n) Fitment of bearing set: the bearing bushes shall have an easy sliding fit with the fulcrum and rodhanger housing and the lugs shall engage fully without excessive clearance. The handle should also have a reasonably good surface contact with stopper plates at upper and lower stroke position.5 mm 85 microns Gauge No.5 mm 6 Flange hole diameter Ø78 +/-0. k) The flanges shall be reasonably flat to provide proper matching. blisters. the rotation between the two bearing bushes should be freely. Description Dimension to be checked 1 Overall height 466 +/-4 mm 2 Height of over flow cover 140 +/-2 mm 3 Distance between plates of fulcrum bracket 120. 3.2 mm 5 Centre distance of flange holes 180/140 +/-0.5 +/-0. Table 45 Dimensions A) Pump head assembly B2003 (Mild Steel welded and hot dip galvanized) No. pumprods and plunger rods shall be examined for diameter. rust stains.h) Top rods. i) Welding defects like cracks. Use of force for insertion of flange bolts or anchor bolts is not permissible.2 +0.1/0 mm shall be tight 110 mm (max.5/0 mm 16.2 Dimension Check List for Afridev Handpumps and Spare parts The inspector shall carry out the following dimensional checks on at least two sample pumps and all the sampled spare parts. o) The stainless steel sleeves shall not protrude beyond the end faces of the fulcrum housing and the rodhanger.5/0 mm 4 Slot width in fulcrum bracket 16. pin holes and discontinuity. E0015 E0027 E0010 . the inspector can carry out detailed dimensional checks on all sampled pumps. lumps. 1 2 3 4 5 6 7 8 Description Bearing diameter (fulcrum housing) Check for slipping of sleeve Length of the fulcrum housing Slot width in fulcrum housing Distance between handle forks Slot width in handle forks Distance of slot position Galvanizing thickness 41 (Mild Steel welded and hot dip galvanized) Dimension to be checked Ø47 +0.3. E0009 E0010 E0026 Gauge No.5 +0. m) Free movement of handle in pump head after assembling.2 +0.2 mm 225 +/-1. The bearing bushes shall have an easy sliding fit with the fulcrum and hanger pin and it should be possible to take them out without using force or the help of any tool. white deposits. The quick coupling device shall be checked for in-line attachment of eye and hook to the rods.5 +0. easy movement of handle rear in handle front before fastening the M16 hex.5 mm 7 Spout length as per purchase order 300 or 580 mm 8 Galvanizing thickness 70 to 80 microns B) Handle front assembly B2013 No. weld/filet size and uniformity. j) Hot dip galvanizing defects like poor adherence of coating. fitment of threads or hook with eye connectors and pumprod centraliser.) 6. q) The rodhanger shall fit easily in between the forks of the handle assembly and into the 16. In assembled position. The details of dimensional checks that need to be carried out on pumps and spare parts are given below.2/0 mm slots. surface uniformity and coating thickness. positional accuracy of components and workmanship.3 +/-0. bolt. l) Stroke length of 225 +/-6 mm.

5/0 mm 4 Check for slipping of sleeve shall be tight 5 Gap between shoulder and hexagonal nut 12 +/-1 mm G) Gauge No.7 +/-0.2/0 mm M16 6. 1 2 3 4 5 6 (Mild Steel welded and hot dip galvanized) Description Dimension to be checked Internal dimension 154 +/-2 mm Slot width for handle 65 +/-1 mm Slot width for locking nut 18 +/-1 mm Slot width for special nuts of fulcrum pin 32 +/-1 mm Shroud diameter Ø60+/-1 mm Galvanizing thickness 70 to 80 microns H) Bearing set H1) Bearing bush outer C2044 No.2 mm 3 Protruding length of pins (both sides) 4 +0.5 mm 2 Outside diameter Ø38 0/-0. Gauge No. E0015 Gauge No.5 +0. . 1 2 3 4 5 6 Description Bore diameter in hanger bush Check for slipping of sleeve Length of the hanger bush Hole diameter of connector Thread in connector Slot width in hanger bush F) Hanger pin assembly B2033 (Mild Steel welded and hot dip galvanized) Dimension to be checked Ø47 +0. Description 1 Outside diameter 2 Bore diameter 3 Lug width 42 Gauge No.3 +/-0.5 mm 2 Outside diameter Ø38 0/-0. Description Dimension to be checked 1 Length of pin 120 0/-0. E0011 E0014 E0013 Gauge No.) Ø12.5 mm (max.2 mm (Mild Steel electroplated) No.C) Handle rear assembly B2020 No. Description 1 Check for free movement 2 Galvanizing thickness D) (Mild Steel welded and hot dip galvanized) Dimension to be checked in handle front assembly 85 microns Fulcrum pin assembly B2024 (Mild Steel electroplated) No. Description Dimension to be checked 1 Length of pin 69 0/-0.5/0 mm 4 Check for slipping of sleeve shall be tight 5 Gap between shoulder and hex. (Polyacetal POM) Dimension to be checked Ø46.2 mm 3 Protruding length of pins (both sides) 4 +0. nut special 12 +/-1 mm E) Rodhanger assembly B2028 No.2 +0.1 mm Ø42.1/0 mm shall be tight 58.2 mm Gauge No. E0012 E0014 E0013 Cover assembly B2036 No.2/0 mm 6 0/-0.

5 mm Ø14 +/-0. Gauge No. 1 2 3 4 5 Description Inside diameter Outside diameter Thickness Angle Shore A hardness 43 Gauge No.3 mm 31 +/-1 mm 30° 65-75 Gauge No. Description Dimension to be checked 1 Overall height 540 +/-5 mm 2 Centre distance of flange holes 180/140 +/-0. Description Dimension to be checked 1 Overall height 965 +/-5 mm 2 Centre distance of flange holes 180/140 +/-0. Dimension to be checked Ø61.No. E0026 Gauge No.2/0 mm 16 +/-0.9 0/-0. E0026 Gauge No.5 +/-0.5 mm 3 Flange holes Ø14 +/-0.5 mm 4 Centre distance of bottom flange holes 260 +/-0.6) Dimension to be checked Ø41.5 mm 4 Position of legs with respect to flange 80° +/-5° (as per drawing) 5 Legs (angle iron) 40/40 x 6 mm 6 Ventilation hole existence of Ø8 mm hole 7 Galvanizing thickness 70 to 80 microns J2) Stand assembly B2221 (Mild Steel welded and hot dip galvanized) No.5 mm 7 Ventilation hole existence of Ø8 mm hole 8 Galvanizing thickness 70 to 80 microns J3) Anchor assembly B2083 No.5 mm 70 to 80 microns L) Compression cone C2095 (Nitrile Rubber) No. 1 2 3 J) H2) Bearing bush inner C2045 Description Outside diameter Bore diameter Lug width (Polyamide PA6.5 mm Ø120 +/-1.5 mm 45 +/-1 mm K) Steel cone assembly B2092 No.2 mm Ø38 +0.3 mm Stand arrangements J1) Stand assembly B2050 (Mild Steel welded and hot dip galvanized) No. . 1 2 3 4 5 Description Steel cone angle Minor end diameter Centre distance of flange holes Flange holes Galvanizing thickness (Mild Steel welded and hot dip galvanized) Dimension to be checked 60° Ø76 +/-2 mm 180/140 +/-0.5 mm 5 Bottom flange holes Ø18 +/-0.5 mm 6 Bottom flange centre hole Ø180 +/-0.5 mm 3 Flange holes Ø14 +/-0. E0026 Gauge No. Description 1 Centre distance of hexagonal bolts 2 Thread length of M16 x 150 bolts (Hexagonal bolts of Stainless Steel) Dimension to be checked 260 +/-0.

Dimension to be checked Ø75 +0.3/0 mm Gauge No. Dimension to be checked 135 0/-3 mm Ø63.1 mm Ø49 0/-0.5/0 mm Gauge No.6 0/-0. E0016 Gauge No.3/0 mm 700 +/-2 mm Gauge No.4 mm Ø3 +/-0.6/0 mm Ø12 +0. Description 1 Inside diameter 2 Thickness 3 Shore A hardness No.1/0 mm 35. 1 2 3 4 5 6 44 N1) Suction pipe C2081 Description Outside diameter Length Bell length Bell mouth diameter (inside) Wall thickness Hole diameter (PVC-U) .6 0/-0. 1 2 3 4 M2) Footvalve receiver C2074 Description Inside diameter Length of bore (Ø33) Outside diameter O-Ring groove (Polyacetal POM) Dimension to be checked Ø33 +0.2 mm as per drawing (Brass) No.3 0/-0.6 +0.2 mm Ø62 0/-0.2 mm Ø75 +0.2/0 mm Ø50 +0.5 0/-0. 1 2 3 4 5 M1) Cylinder pipe C2072 fitted with Liner C2073 Description Overall length Machined length (bottom end) Outside diameter Inside diameter of sleeve Length of sleeve No.1 mm 7° +/-15’ Ø49. 1 2 3 M5) Reducer C2080 Description Overall length Inside diameter Outside diameter (PVC-U and Brass) Dimension to be checked 850 +/-10 mm 110 +5/0 mm Ø63 +0. Dimension to be checked Ø44.5 mm as per drawing Gauge No.3/0 mm 1000 +/-10 mm 75 +/-5 mm Ø75.2 mm 3. 1 2 3 4 5 M3) Footvalve receiver C2299 Description Inside diameter Angle of cone Outside diameter Outside diameter of flange O-Ring groove M4) O-Ring C1020 No. E0020 (Nitrile Rubber) (PVC-U) N) Suction pipe No.15 mm 65-75 Gauge No. E0020 Dimension to be checked Ø48 +/-0.2 +/-0.M) Cylinder parts No.

6 +0. (Brass) Dimension to be checked Rd30 x 3.6 +0.6 mm 2 Hole diameter (for Ø10 or Ø12 mm pumprods) Ø11 or Ø13 +/-0. 1 2 3 4 5 6 O3) Top sleeve C2042 Description Sleeve inside diameter Sleeve length Wall thickness of socket (PVC-U) No.3/0 mm 850 +/-10 mm 4.2 mm 4.8/0 mm Ø63. smooth surface as per drawing C2757 Gauge No.175 30° +/-30’. E0040 .5 +/-0.7 +0.3/0 mm 3000 +/-25 mm 4. Dimension to be checked Ø63 +0.2 mm 80 +/-2 mm 5.5/0 mm Gauge No.7 +0.2 mm 200 +/-5 mm 5. Dimension to be checked Ø63 +0.3/0 mm Ø63. Plunger assembly A2266 P1) Plunger body C2757 No.5mm Ø62.5 mm 24 +/-1 mm 70-80 Gauge No.5 0/-0. Dimension to be checked Ø63.9/0 mm Gauge No. Description 1 Connecting thread 2 Valve seat 3 Cup seal groove 45 (Nitrile Rubber) Dimension to be checked Ø140/118/100/92 +/-0.7 +0.5 mm No. 1 2 3 4 P) O5) Centraliser 2076 / 77 / 78 / 79 Description Outside diameters Inside diameter Thickness Shore A hardness Gauge No. 1 2 3 O4) Flapper C2043 (HDPE or Rubber) No. 1 2 3 4 O1) Riser pipe C2046 Description Outside diameter Bell mouth diameter (inside) Wall thickness Length (PVC-U) O2) Riser pipe assembly B2106 Description Pipe outside diameter Pipe length Wall thickness of pipe Socket inside diameter Socket length Wall thickness of socket (PVC-U) No. Description Dimension to be checked 1 Outside diameter Ø 80 +/-1.3 0/-0.8/0 mm 2900 +/-25 mm Gauge No. O) Rising main pipe No.8/0 mm Ø12 +0.9/0 mm Gauge No. 1 2 3 4 N2) Suction pipe C2262 Description Outside diameter Length Wall thickness Hole diameter (PVC-U) Dimension to be checked Ø63 +0.5 0/-0.No.

E0022 (Stainless Steel welded) Q4) Fishing connector C2220 No. Description 1 Connecting thread 2 Other threads R2) O-Ring C1011 No. 1 2 3 4 5 R1) Footvalve body C2759 or C2761 Description Outside diameter Angle of cone Angle of valve seat Valve seat and cone O-Ring groove 46 Gauge No. 1 2 3 Q3) O-Ring C1021 Description Inside diameter Thickness Shore A hardness Dimension to be checked as per drawing C2090 M10 Gauge No. Description 1 Eye 2 Thread No.15 mm 65-75 Gauge No. (Nitrile Rubber) Q) Footvalve arrangement A2096/A2265 Q1) Valve body assembly B2085 No. Dimension to be checked Ø28 +/-0. (Nitrile Rubber) R) Footvalve arrangement A2298 No. Description 1 Dimensions 2 Shore A hardness (Nitrile Rubber) Dimension to be checked 44 +/-1 mm Ø26 +/-0.35 mm Ø2.No. Description 1 O-Ring groove Q2) Eye assembly B2089 No.35 mm Ø4 +/-0.25 mm 30º +/-30’ (no flash allowed) 70-80 Gauge No. Dimension to be checked Ø39 +/-0. Dimension to be checked Rd30 x 3.1 mm (theoretical) 7° +/-15’ 30° +/-30’ machined smoothly as per drawing Gauge No.15 mm 65-75 Gauge No. 1 2 3 4 5 P2) Bobbin C2088 Description Total length Outside diameter Outer diameter (of fins) Angle of valve seat Shore A hardness P3) Cup seal C2758 No. Dimension to be checked as per drawing C2758 80-90 Gauge No. Description 1 Inside diameter 2 Thickness 3 Shore A hardness (Polyacetal POM) Dimension to be checked as per drawing (Brass) (Brass) E0039 (Nitrile Rubber) .5 +/-0.35 mm Ø18 +/-0.175 M10 and M6 Gauge No. Dimension to be checked Ø47 +/-0.

1 2 3 4 S1) Top rod assembly B2207 Description Rod diameter Rod length Coupler Galvanizing thickness (threaded.S) Pumprod arrangement A2206 No.2 mm (bright) 2990 +5/0 mm as per drawing C2215 as per drawing C1053 (welded) Pumprod arrangement A2110 Gauge No. U) (Hook & Eye. Description 1 Rod diameter 2 Rod length 3 Coupler 47 Gauge No. Stainless Steel) (welded) Dimension to be checked Ø10 +/-0. Gauge No.2 mm (bright) 2990 +5/0 mm as per drawing C2215 Gauge No.5 mm 20 +/-1 mm 70-80 (threaded. (Nitrile Rubber) T1) Top rod assembly B2210 No.2 mm (bright) 1000 +/-3 mm as per drawing C1053 Gauge No. Stainless Steel) (welded) Dimension to be checked Ø12 +/-0.2 mm (bright) 2990 +5/0 mm as per drawing C2213 as per drawing C1012 70 to 80 microns S3) Centraliser C2212 No.2 mm (bright) 2990 +5/0 mm as per drawing C2213 70 to 80 microns No. 1 2 3 4 Gauge No. Mild Steel) (welded and hot dip galvanized) Dimension to be checked Ø12 +/-0. . 1 2 3 4 5 S2) Pumprod assembly B2214 Description Rod diameter Rod length Coupler Coupler Galvanizing thickness (welded and hot dip galvanized) Dimension to be checked Ø12 +/-0. Description 1 Rod diameter 2 Rod length Gauge No. (welded) T3) Plunger rod assembly B2258 No.2 mm (bright) 2800 +/-10 mm U1) Top rod assembly B2111 No. Description 1 Outside diameter 2 Hole dimension 3 Thickness 4 Shore A hardness T) Pumprod arrangement A2209 T2) Pumprod assembly B2216 Description Rod diameter Rod length Coupler Coupler Dimension to be checked Ø48 +/-1 mm Ø16 +/-0. Dimension to be checked Ø12 +/-0. Description 1 Rod diameter 2 Rod length 3 Coupler No. Dimension to be checked Ø12 +/-0.

pultruded) Dimension to be checked Ø10 +/-0.1/0 mm 5° +/-15’ (smooth surface) 23 +/-0.5 mm Gauge No. Description 3 Hook 4 Pumprod centraliser U2) Pumprod assembly B2114 No.2 mm Gauge No. Description 1 Rod diameter 2 Rod length 3 Eye 4 Adaptor (welded) V) Gauge No. Dimension to be checked Ø10 +/-0.2 mm (bright) 2800 +/-10 mm as per drawing C2112 as per drawing C2115 Gauge No.No. Description 1 Outside dimension 2 Hole dimensions 3 Angle of cone 4 Length (Brass) V4) FRP Pumprod C5894 No. Description 1 Outside dimension 2 Length 48 Dimension to be checked as per drawing C2112 as per drawing C2109 Dimension to be checked M20 and Ø16 +/-0.5 mm Ø10. Dimension to be checked Hexagonal bar. Dimension to be checked Ø10 +/-0.1 mm 5° +/-15’ (smooth surface) M20 45 +/-0. Description 1 Rod diameter 2 Rod length 3 Hook 4 Eye (welded) U3) Plunger rod assembly B2116 No.1 +0. 60-70% glass fibres.2 mm (bright) 735 +/-5 mm as per drawing C2115 as per drawing C1156 Gauge No. Description 1 Outside dimension 2 Hole dimensions 3 Angle of cone 4 Connecting thread 5 Length (Stainless Steel) V3) Collet C5893 No.1 mm 3000 +10/0 mm (6000 mm) Gauge No.5 mm Gauge No.1 +0.1/0 mm 70 +/-0. Description 1 Outside dimension 2 Hole dimension 3 Length (Brass) V2) Union nut C5892 No.2 mm Ø10. 24 mm A/F Ø14 +/-0. Pumprod arrangement A5889 (A5896 and A5890) V1) Connector C5897 No. Dimension to be checked Ø17 0/-0. (Polyester. .

5 mm Gauge No.V5) Connector C5897 Description Outside dimension Hole dimension Thread Length (Brass) No. Description Dimension to be checked 1 Rod length (Ø10 mm) 1500 +/-5 mm 2 Connecting Eye welded as per drawing C2115 3 Galvanizing thickness 70-80 microns 4 Check for engagement of fishing hook with footvalve assembly A2096 49 Gauge No. 1 2 3 4 No.1 +0.5 mm Dimension to be checked M20 and Ø20 +/-0.1/0 mm M12 64 +/-0.5 mm Ø14 +/-0. Gauge No. Description 1 Centre distance of flange holes 2 Flange holes 3 Slot for hexagonal coupler 4 Slot for Pumprods (Mild Steel welded and electroplated) Dimension to be checked 180/140 +/-0.2 +/-0.5 mm W3) Connecting tool assembly B2420 No. Gauge No. Gauge No. Description 1 Socket inside dimensions 2 Length of Handle rod (Mild Steel welded and electroplated) Dimension to be checked AF 24. E0026 Gauge No.5 mm Ø10. Description 1 Rod length 2 T-bar length 3 Hexagonal coupler (Mild Steel welded and electroplated) Dimension to be checked 200 +/-10 mm 200 +/-10 mm as per drawing C1015 W4) Fishing tool assembly B2097 (Mild Steel welded and hot dip galvanized) No. Check for interchangeability of all sampled assemblies.1 mm 300 +/-5 mm W2) Resting tool assembly B2415 No.2/0 mm 13 +/-0. Description Dimension to be checked 1 Rod length (Ø12 mm) 1500 +/-5 mm 2 Connecting thread M12 3 Galvanizing thickness 70-80 microns 4 Check for engagement of fishing hook with footvalve assembly A2096 W5) Fishing tool assembly B2150 (Mild Steel welded and hot dip galvanized) No. W) Tools for Installation and Maintenance W1) Spanner assembly B2160 No. .5 mm 19 +0. 1 2 3 4 5 V6) Coupler C2215 Description Outside dimension (hexagonal) Groove inside Groove width Thread Length (Stainless Steel) Dimension to be checked 19 A/F Ø16 +0.5/0 mm M12 50 +/-0.5/0 mm 21 +0. Gauge No.

4 Inspection of PVC-U Riser pipes Inspection of PVC-U riser pipes is also carried out if it is included as a part of the handpump order. if test facilities are not available at the pump manufacturer’s premises. All the packing cases will be stuffed into a container in the presence of the inspector for certification. stuffing and loading. 50 . Performance test shall be conducted on a test rig. specific checks shall be carried out on samples drawn. shall verify: • the quality of packing. The sampling plans for specific tests together with a brief description of each test is given in Annex XII. 3.5 litres in forty complete and continuous strokes in one minute. • the quantity of parts as per packaging list prepared by the manufacturer and • identification marks on packages/packing cases. tags and packing cases. 3.3. the whole lot shall be treated as rejected. unless specifically asked by the buyer. Discharge of water shall not be less than 16. when required by the buyer. 1 2 3 4 5 6 Marking of Pump Assemblies Description on all pump heads on all pump handles on all pump stands on pumprod bundles on all cylinders on riser pipe bundles Marking type steel punch steel punch steel punch steel punch ink mark ink mark Place of Marking on flange on left fork near fulcrum housing on flange Lead seal attached to each pumprod bundle on outside diameter of pipe on outside diameter of pipe For spare parts the following marking procedure will be adopted. The inspector. b) The packing list verified by inspector shall be marked with the inspector’s ink stamp.6 Important Points to Remember The following shall be kept in view before clearing the materials for packaging. Inspection of riser pipes should be carried out in the laboratory of the pipe producer. Identification and markings shall be done as per the PVC-U pipe specification. 3.3. Buyers are advised to include these aspects in the scope of IIA inspection wherever necessary. the assemblies and components will be stamped as per inspection stamping procedure given in Table 46. c) The clearance will be issued for packaging of pumps and spares after acceptance and stamping of the material. f) The IIA inspectors normally do not carry out checks during packing.3. The procedure for inspection checks shall be given in ISO 2859-1. b) If the samples components/assemblies satisfy all the above checks and performance test. a) For spare parts the packing cases shall be marked with the inspector’s ink stamp.3. The packing list shall be attested by the inspector for its correctness. d) The pumps and spares shall be packed. In addition to verification of manufacturer’s test certificates and general visual checks on all riser pipes. a) If the rejected quantity is more than the acceptable number of the sampling plan. Table 46 No.5 Inspection and Marking Procedure The inspection and marking (stamping) procedure for pump assemblies and riser pipes shall be as given in the table below. e) The packing shall be closed and sealed with lead seals attached to the straps.3 Performance Test After satisfactory inspection of attributes and variables a minimum of two cylinders irrespective of lot size shall be selected at random from the sample lot for performance test for water discharge.3. The container shall be finally sealed by the inspector.

after satisfactory inspection of the handpumps or spare parts.3. The original copy shall be given to the manufacturer and a copy forwarded to the buyer for information. The details of pre-delivery inspection stamping details as marked on assemblies and inspected bundles/packages shall be indicated in the acceptance note. The acceptance note will be specifically designed and printed in sets of copies by the IIA and shall be singed by the authorised inspection personnel. A typical format for rejection note is given in Annex XIV. The acceptance notes shall be numbered and a register for all acceptance notes shall be maintained by the IIA. The details of steps to repair/replace the defective materials and avoid repetition of such non-conformities shall also be informed to IIA.3. (b) One copy will be sent to the purchaser and (c) One copy will be retained by the inspection agency’s office.7 Issue of Acceptance/Rejection Note Acceptance Note: The IIA. reasons for rejection and quantity rejected. the manufacturer shall investigate and take corrective/preventive action to eliminate defects. Based on the non-conformance mentioned in the rejection report. 51 . It will give specific details of non-conformity. The manufacturer after taking required corrective action shall approach the IIA for a re-inspection of the materials. shall issue an acceptance note (suggested format given in Annex XIII). Rejection Note: The inspector will issue a rejection note if the material is considered to be unacceptable due to non-conformance to purchase order requirements. if the materials offered conform to the quality requirements specified in the purchase order. Distribution of acceptance note shall be as follows: (a) Original plus one copy to the manufacturer.

4. e) Check whether packing slip of manufacturer. handle. 4. 4. b) Check for proper welding. 52 .2. d) Check for free movement of handle rear in handle front and for free movement of handle in pump head.2. stand assembly etc. a joint inspection involving inspection agency. customer/purchaser and manufacturer is recommended. f) Check if all fasteners (bolts and nuts) required for installation have been supplied. In case of a major discrepancy. filler size and uniformity of weld surface defects like blow holes. c) Check the fit of the pre-assembled plunger in the cylinder.1 Fabricated Parts Check fabricated items like pump head assembly. The procedure for customer’s end inspection is given below.4. 4. b) Check size and straightness of the cylinder with plug gauge E0016.2 Cylinder Assembly Check for any breakage of packing cases and damage caused if any to the cylinder assemblies.3 Reporting and Follow-Up In case of any deficiencies. The customer’s or purchaser’s end inspection is normally carried out by an authorised representative of the customer/purchaser. c) Check for damages on spout. stand. The report shall be forwarded to the pump manufacturer and the inspection agency for necessary actions. c) Interchangeability of connectors (threads or hook & eye). handle assembly. c) Check whether all materials are received in packed condition (without damage to seal or tampering of packages) as per packaging standards specified. b) Check for inspection stamp on pumprod bundles.3 Pumprod Bundles Check for proper packaging with quantity as per packing slip and the following details: a) Check for manufacturer’s identification marks. Measuring and Testing Instruments required for End Inspection are found in Annex XV. cracks.0 End Inspection of Delivered Products (for customers) The main objective of the customer’s end inspection is to ensure that only inspected and accepted materials are received by the buyer (customer). 4. etc. 4. Check the cylinder details as follows: a) Check smoothness of cylinder (brass inner) for any dents or other damages.2. a consolidated report of discrepancies/findings is prepared by the customer or purchaser. as follows: a) Check for flatness of flanges with a steel ruler in case of transit damage. legs etc.2 Specific Checks The specific checks required to be carried out at random to confirm that the materials comply to the specifications. e) Check for any corrosion or pitting. quantities mentioned in the supplier’s invoice and quantity of goods received are in order.1 General Checks The general checks recommended are given below: a) Check whether copy of acceptance note is furnished along with despatch documents. d) Check whether all the assemblies and bundles/packages are stamped as specified in the acceptance note.

............. Date: ............................................................................................................... ......................................................Annex I Format for Manufacturer’s Deviation Report Name of Manufacturer Report No...................................................................................... ...... Corrective Actions taken: ...... ................................................. Signature of Workshop Manager: ................................................................................................... Drawing No........................................................................................................…………............................................................................................................ No........................................................................................................................ ............................................................. ..... . Part/Assembly Name Date ..... Place: ........................................................……………….................. Signature of Inspector: ..................................... Corrective Actions suggested: ................................................. ............ Details of Deviations Name Inspector: ................................................................................................................................................... 53 ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................

GO and NO-GO 54 Size/Dim.Annex II List of Measuring Instruments for Afridev Tools recommended for the production and the Internal Quality Control (QC) No.and Hanger pin (holes for locating pin) 2 Thread plug gauge M10-6H Footvalve fitting and Hexagonal nuts 3 Thread ring gauge M10-6g Hexagonal bolts 4 Thread plug gauge M12-6H Pumprod connectors.01 mm 1 1 7 Micrometer 25-50 mm 0. set of 49 pieces 0-100 grade 1 -- 19 Magnifying lens at least 3 x size 1 -- 20 Hardness tester 0-100 Shore A (Rubber) 1 -- 21 Elcometer 0-100 micron 1 -- 22 Spirit level 300 mm 1 1 22 Magnet for checking Stainless Steel parts 1 1 24 Master gauges For checking all checking tools used for production --- 1 Set Annex III 0. 600 x 600 mm 1 -- 15 V-Block 100 x 100 x 90º 2 -- 16 Dial gauge 0-10 mm 1 -- 17 Magnetic stand 250 mm 1 -- 18 Slip gauges.02 mm 1 1 5 Sliding calliper 300 0.02 mm 1 1 6 Micrometer 0-25 mm 0.01 mm 1μ 0. Plunger body and Hexagonal nuts 5 Thread ring gauge M12-6g Pumprod threads and Hexagonal bolts 6 Thread plug gauge M16-6H Rodhanger thread and Hexagonal nuts 7 Thread ring gauge M16-6g Fulcrum. Gauge used for 1 Plug gauge Ø6-H7 Fulcrum.1 mm 0.and Hanger pin threads and Hexagonal bolts . Description Size and Accuracy Workshop Internal QC 1 Measuring tape 2m 1 mm 1 1 2 Steel ruler 300 mm 1 mm 1 1 3 Steel ruler 500 mm 1 mm 1 1 4 Sliding calliper 150 mm 0.1/m List of Standard Gauges for Afridev Standard gauges recommended for the Internal Quality Control No.01 mm 1 1 8 Bevel protractor (mechanical) 0-180º 10” 1 1 9 Radius gauges (inside) 1-15 mm 1 Set -- 10 Radius gauges (outside) 1-15 mm 1 Set -- 11 Thickness gauge 0-10 mm 1 Set 1 12 Try square 150 mm 1 1 13 Try square 300 mm 1 -- 14 Surface plate (cast iron) approx.

E0026 Slot gauge for Bracket plate and Handle forks.0 Ø29.1 30. C2112 and C2122 Footvalve receiver C2074 Valve body assembly B2085 Special gauges recommended for the Internal Quality Control Annex V List of Special Testing Equipment for Afridev Equipment No.4 Ø44.7 120.0 10. 1 3 Testing equipment for Discharge Test of finished Pumps 1 . 1 Testing equipment for Load Test of spin-welded Valve body parts 1 2 Equipment for Leakage Test.4 Where used -----.2 30. 1 bar and 10 bar for Cylinder assy. C2115 and C2125 Hook C2102. E0011 Snap gauge for Hanger pin and assembly.drawing No.3 16. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 GO Template for centre distance of holes in Flanges.3 10.8 Ø47.7 68. E0013 Ring gauges for Fulcrum and Hanger pin assembly.9 3.5 12.7 68. E0010 Distance gauge for Fulcrum bracket assembly. E0027 Snap gauge for Fulcrum pin and assembly.5 10. (only forged version) E0019 Snap gauge for O-Ring groove on Footvalve receiver. Flanges C2005 / C2053 and Steel cone assembly B2092 Bracket plates C2007 and Handle forks C2014 and C2015 Fulcrum bracket assembly B2006 Handle front assembly B2013 Fulcrum pin C2025 (assembly B2024) Hanger pin C2034 (assembly B2033) Fulcrum pin assembly B2024 Hanger pin assembly B2033 Fulcrum pin assembly B2024 Hanger pin assembly B2033 Handle front assembly B2013 Rodhanger assembly B2028 Cylinder assembly B2297 / B2071 Eye C2105.3 29.1 Ø50.1 Ø44. E0022 (for drawings see Annex XVII) NO-GO 140/180 (or 70/90) 16. E0016 Slot gauge for Eye.8 Ø29.0 Ø38.0 Ø47.1 3. E0009 Distance gauge for Handle front assembly. E0014 Plug gauge for Handle front and Rodhanger assembly. E0020 Snap gauge for O-Ring groove on Valve body assembly. E0012 Gap gauges for Fulcrum and Hanger pin assembly.8 69.5 119.2 120.Annex IV List of Special Gauges and Templates for Afridev Special gauges recommended for the Internal Quality Control No.3 68. 55 Description Qty. E0015 Plug gauge for ID of Sleeve in Cylinder assemblies. (only forged version) E0017 Snap gauge for Hook.0 Ø37.8 119.8 4.0 10.0 Ø50.3 30.3 3.

Side plates. Spacer and Washer 11 Plunger rod assembly Welding of Rod. Stand pipes. Legs and Gussets 7 Steel cone assembly Welding of Eyes 8 Footvalve fitting assy. Shrouds and Deflector 6 Stand assemblies Welding of Flange. 56 . Connector. Eye & Hook. Handle pipe and Hexagonal nut 3 Handle rear assembly Welding of T-Bar and Extension pipe 4 Rodhanger assembly Welding of Hanger bush. Fulcrum housing. SKAT-RWSN). Side plates. Movable clamp and Hinge Annex VII List of Welding Tools for Afridev No. Fulcrum bracket assembly. Hook and Spacer 10 Pumprod assembly Welding of Rod.Annex VI List of Bending Tools for Afridev No. Back plate and Top plate 1b Flange assembly Welding of Flange and Stopper 1c Fulcrum bracket assy. Name of tool Description 1 Cylinder Heat-shrinking of Cylinder pipe over Liner 1 Steel cone Deep drawing of Cone plate 1 Reducer Flaring of Reducer For examples of appropriate Jigs and Fixtures see Annex IX (photographs made by Meera Pumps Ltd. Retainer bush and Hex. Name of bending tool Description 1 Cover Bending of Cover plate 1a Shroud Bending of Shroud 2 Leg Bending of Legs (only for Concrete stand) 3 Eye & Hook Bending of Eyes and Hooks for Pumprods 4 Fishing tool Bending of Side plates 5 Iron clamp Bending of Fixed clamp. Spout assembly. Back plate and Eye Annex VIII List of other Manufacturing Tools for Afridev No. Erpf. Cover plate. Eye and Washers 12 Fishing tool assembly Welding of Rod. Name of welding tool Description 1 Pump head assembly Welding of Body assembly. Spout end and Reducer 2 Handle front assembly Welding of Forks left & right. Welding of Eye and Connector 9 Top rod assembly Welding of Rod. Overflow cover & Hexagonal nut 1a Body assembly Welding of Channel. nut 5 Cover assembly Welding of Cover plate. Flange assembly. India and K. Welding of Bracket plate and Stopper plate 1d Spout assembly Welding of Spout pipe. Hyderabad.

B2082 Tack welding fixture for Stand assy. B2082 57 .Annex IX Examples of Manufacturing and Testing Jigs & Fixtures for Afridev Milling jig for cutting 15° angle on Handle forks Tack welding fixture for Rodhanger assy. B2050 Tack welding fixture for Rodhanger assy.

Tack welding fixture for Fulcrum bracket B2006 Tack welding fixture for Pumphead / Spout Tack welding fixture for Handle front assy. B2013 Tack welding fixture for Cover assembly B2036 58 .

Checking galvanized zinc layer of Steel cone assy. B2085 59 . B2028 Checking OD of Fulcrum pin assy B2024 Testing equipment for spin-weld strength of Footvalve assy. B2092 Checking M16 thread of Rodhanger assembly B2028 Checking ID of Rodhanger assy.

: __________________________________________ E-mail address: _______________________________________ 2. =2 =1 =0 F . Production facilities Machine-tools & equipment Jigs & Fixtures for machining 60 yes: yes: yes: yes: yes: yes: yes: yes: yes: yes: good/clean =2 =2 satisfactory =1 no: =1 no: =1 no: =1 no: =1 no: =1 no: =1 no: =1 no: =1 no: =1 no: Export: ____% rating F F F F F F F F F F =0 =0 =0 =0 =0 =0 =0 =0 =0 =0 sufficient =1 =1 poor =0 =0 rating F F Gauges & Instruments for checking machined components Welding equipment Jigs & Fixtures for welding =2 =2 =2 =1 =1 =1 =0 =0 =0 F F F Gauges & Instruments for checking welded assemblies Galvanizing facilities =2 =2 =1 =1 =0 =0 F F Assembly of pump components Cylinder. Plunger / Footvalve etc. Infrastructure Store for raw material: Production / Fabrication: Welding section: Hot dip galvanizing: Assembling section: Inspection section: Laboratory / Testing: Store for finished products: (including bought-out items) Office & Storage of documents: 4. Particulars Name of pump manufacturer: Address: ____________________________________________ ____________________________________________________________ ______________________________________________________________________ Place / Country: _______________________________________ Phone No. General Information Pump manufacturing since: _________ Pump Types produced: ______________ Manufacturing capacity per month: ___________ Pumps Total units produced per year: _______ Domestic use: ____% Manpower: skilled personnel: _______ unskilled personnel: _____ Total: _____ 3.: __________________________________________ Fax No.Annex X Format for Evaluation of Handpump Manufacturers 1.

15 points = questionable performance 16 . Ratings Addition of all ratings = ______ points Performance according to rating points: . Inspection & Testing facilities good/clean Tools for Inspection (Master gauges) =2 Devices for testing Pump assemblies (and performance testing) =2 sufficient =1 poor =0 rating F =1 =0 F 6.25 points = acceptable performance 26 .46 points = excellent performance Date of evaluation: ____________________ * These processing facilities need to be evaluated separately 61 not recommended for Pump procurement Pump procurement possible (with limitations) recommended for Pump procurement recommended for Pump procurement Signature of evaluator: ______________________ . General Findings good/clean Condition of Infrastructure =2 Condition of Machine tools =2 Condition of Jigs & Fixtures =2 Condition of Gauges & Checking tools = 2 Condition of Documentation =2 Quality of Workmanship =2 Quality of Galvanization =2 sufficient =1 =1 =1 =1 =1 =1 =1 poor =0 =0 =0 =0 =0 =0 =0 rating F F F F F F F 6.35 points = good performance 36 .Other processing facilities * Plastic Injection moulding PVC-U Pipe extrusion Rubber moulding available yes: = 1 no: = 0 yes: = 1 no: = 0 yes: = 1 no: = 0 F F F 5.

........... Unit Price Total Price (a) Supply of ..... (Carbon Steel or Stainless Steel) *b) Pumprod assembly...... Purchase Order No....... Fax No...... .. Rod hanger assembly etc.... ....… drawing No... .....5”/5”/6”/8”) drawing No... complete *Stand assembly (long stand/short stand/concrete stand) drawing No.......... Price: Description Qty......: . …. Handpump complete as per SKAT-RWSN Specification and described below (b) Supply of spare parts as per attached list ** 2. ... E-mail No.. .................. invoices.................. Forwarding instructions ……………… Date ……………… Supplier’s Reference: Bid No.. .......... X h drawing No.... Stainless steel.. d Steel cone with Compression cone X e Rising main pipe X f Top sleeve...: .......... 1............ Description a *Pump head with Cover (Spout length 300 or 580 mm to be specified) X b X c Handle assembly with Fulcrum..............…… Remarks: ....… drawing No........... X g *Centraliser for Rising main pipe................ Opened on ...and Rod hanger pins.............. Phone No.................................... (Carbon Steel or Stainless Steel) c) Plunger rod assembly............... (All shipments. Ball bearings.... Flapper including Solvent cement and Cleaning fluid etc.....meters X ... B7117 i *a) Top rod assembly............. .... X m Fishing tool X n Iron clamp (one clamp per 2 m depth) X o Spanner X p *Rope Ø8 mm (exact length to be indicated) *Indicate appropriate option and/or quantity ** Use the attached format while ordering spare parts 62 Qty. Please supply the following material as per terms and conditions given below... Pumprod centralisers (one Centraliser per Pumprod) X X X X k Cylinder assembly l *Suction pipe (used for Boreholes or Dug wells) X X drawing No...........: ...... Description: Each set consists of the following Item No....... (4”/4.... correspondence must indicate this Number) Date ……….Annex XI Purchase Order Format for Afridev Name of supplier: ......

...... 9......................Additional terms and conditions of purchase order: 1...................................................................... 6.................................. (Name and designation of ordering authority) Return one copy attesting acceptance of the order Order Acceptance Signature: ......................................... 3.................. 4.......... number of copies of each document to be forwarded)......................... 5........... ............ Mode of resolving receipt of defectives/damages....................... ... Penalty clause (% of total value of order will be charged for every week of delay in dispatch)....... Pre-delivery inspection by independent inspection agency (give name and address of Inspection agency)..................... 14................. ............. 2. Dispatch Details Mode of Transport and Destination address (Purchaser’s address).......... 15. 8............................................ Marking (indicate if any particular marking is required).................... 12.... Guarantee Clause (indicate whether as per SKAT-RWSN specification or any other specific clause)...................................................... Circumstances leading to purchase order cancellation......... Prices Indicate whether prices are: a) on FOB or CIF or ex-factory basis b) inclusive or exclusive of taxes c) inclusive or exclusive of packing charges............................ Paying authority Name of person who needs to be contacted by manufacturer for settlement of invoices & documents to be submitted with the invoice................................. . Delivery Schedule (indicate if part delivery acceptable or not)............................... Arbitration Enclosures: Suitable clause to be included...................... Earnest Money Deposit and forfeiture clauses.............................. Packaging instruction (indicate the type of packing or any specific requirements).. Documents to be forwarded for payment of invoices (give clear instructions regarding documents to be submitted with the invoice............................ 7.......... 11...... ......... Terms for payment 10..... (Name and Designation of supplier) 63 ............................................ 13................................................................................ Signature: .............................

Description SKAT-RWSN No.Format for Ordering Afridev Handpump Spares No. (Spout 300 or 580 mm) B2003 2 Hexagonal bolt M12 x 40 mm C1017 3 Hexagonal bolt M16 x 25 mm C1025 4 Hexagonal nut M16 C1018 Pump handle --- 5 Handle front assembly B2013 6 Hexagonal bolt M16 x 25 mm C1025 7 Handle rear assembly B2020 8 Fulcrum pin assembly B2024 9 Rodhanger assembly (for Ø10 and 12 mm) B2028 10 Hexagonal bolt M16 x 16 mm C1105 11 Hanger pin assembly B2033 12 Cover assembly B2036 Bearing set --- 13 Bearing bush outer C2044 14 Bearing bush inner C2045 Pump stands --- 15 *Stand assembly with 3 legs B2050 16 *Stand assembly with Bottom flange B2221 17 Gasket for Stand assembly B2221 C2059 18 Anchor assembly for Stand B2221 B2083 19 Hexagonal nut M16 (Brass) C1130 20 Washer for M16 (Brass) C1069 21 Steel cone assembly B2092 22 Compression cone C2095 Pumprod arrangement --- *Pumprod threaded (Mild Steel) A2206 23 Top rod assembly B2207 24 Pumprod assembly B2214 *Pumprod threaded (Stainless Steel) A2209 25 Top rod assembly B2210 26 Pumprod assembly B2216 27 Plunger rod assembly B2258 28 Centraliser (for Pumprods) C2212 *Pumprod Hook & Eye (Stainless Steel) A2110 29 Top rod assembly B2111 30 Pumprod assembly B2114 31 Plunger rod assembly B2116 32 Centraliser (for Pumprods) C2109 *Indicate appropriate option 64 (Part of Annex XI) . Unit Price Total price 1 *Pump head assy. Qty.

) Bobbin O-Ring Hexagonal bolt M10 x 35 (Stainless Steel) Washer for M10 (Stainless Steel) Push rod *Footvalve (Brass version) complete Footvalve body Bobbin O-Ring Hexagonal bolt M6 x 25 mm (Stainless St.5” casings for 5” casings for 6” casings *Footvalve (Polyacetal version) complete Valve body assembly *Fishing connector (Stainless St.No. Qty.. thread conn.) *Fishing connector (Brass. eye con.) Hexagonal nut M6 (Stainless Steel) Plunger assembly (Brass) Bobbin Cup seal Tools Spanner assembly Resting tool assembly Connecting tool assembly *Fishing tool (with threaded connector) *Fishing tool (with Hook & Eye connector) *Indicate appropriate option 65 SKAT-RWSN No. Unit Price Total price A5889 A5896 C5897 C5892 C5893 C5894 C2109 A5890 C5891 C2215 --B2071 B2297 A2099 or A2119 C2046 B2106 C2042 C2043 C1087 or C1094 --C2079 C2078 C2077 C2076 A2265 B2085 B2089 C2220 C2088 C1021 C1066 C1064 C2760 A2298 C2759 or C2761 C2088 C1011 C1120 C1121 A2266 C2088 C2758 --B2160 B2415 B2420 B2097 B2150 . Description 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 *Pumprod arrangement (FRP) Pumprod connector assembly Connector (Brass) Union nut (Stainless Steel) Collet (Brass) FRP Pumprod Centraliser (for Pumprods) Plunger rod connector assembly Connector (Brass) Coupler (Stainless Steel) Cylinder assemblies *Cylinder assembly *Cylinder assembly Rising main assemblies *Riser pipe *Riser pipe Top sleeve Flapper *Rope 6 or 8 mm (indicate exact length) *Centraliser for Riser pipes for 4” casings for 4.

First 5 5 0 2 Second 5 10 1 2 Stress Relief Test: a 100 mm long pipe is kept in an oven at 150º C for one hour and shall not show blisters. Sample Size Cumulative Sample Size Acceptance No. One sample for every extrusion run is selected and the sample is subjected to 14 strikes. excessive de-lamination.Annex XII Scale of Sampling for PVC-U Pipes (Double Sampling Method) Table A Scale of sampling for Visual Appearance and Dimensional Requirements No. The sample shall not rupture during the test with bar. Table C Scale of Sampling for Stress Relief Test (Double Sampling Method) Sample No. The mass of striker and the height of free fall is based on the table given below: Table F Testing details Nominal Size (mm) Total Mass of Striker (kg) 50 and 75 66 0. First 3 3 0 2 Second 3 6 1 2 Reversion Test: a 300 mm long pipe is immersed in both of Ethylene Glycol or Mineral Oil at 150º C and the length shall not alter more than 5%. No. tests can be carried out in an oven. Table D Scale of Sampling for Internal Hydrostatic Test No. Up to 3000 2 0 Internal Hydraulic Test: a 250 to 750 mm long pipe is connected to hydraulic pressure line at ambient controlled temperature. Up to 1’000 1’001 to 3’000 First Second First Second 13 13 20 20 13 26 20 40 Table B Scale of Sampling for Reversion Test Sample No. All pipes can be tested for one strike as per the table below. of PVC-U pipes Sample Cumulative Acceptance Rejection Sample No. of PVC-U Pipes in Lot Sample Size Acceptance No. cracking or signs of weld line splitting. in Lot Size Sample Size No. Rejection No. Up to 1000 26 0 1001 to 3000 49 0 Impact Test: The test is to be carried out at least 100 mm from the pipe end. No sample shall fail or show signs of fracture.10 . Table E Scale of Sampling for Impact Test No.25 Height of Free Fall (mm) 2000 +/. of PVC-U Pipes in Lot Sample Size Acceptance No. Sample Size Cumulative Sample Size 0 1 0 1 2 2 2 2 Acceptance No. Rejection No.

............................. Order completed/not completed .................. 67 Inspection Agency (Signature) ................ Inspection attended on ……..................................................Annex XIII Format of Acceptance Note by Independent Inspection Agency Name of Inspection Agency Manufacturers Name Person in charge Manufacturers address Dear Sir......................... Description Ordered Qty....................……………............................... Customer ………………………………..............…............................... Place of Inspection ……....................................... Item No........ Total No......................... received on (Date) Inspection Stamping Details: Remarks: .......................... Date: ...................... Concerning: Acceptance Note Reference: 1) Purchase Order No…….... Total No............. Accepted Qty.. ................... Offered Qty......................................................... of Visits ……...........................................................................…………….............. Place: ...........................................................................................................................................................…………….... of items cleared (in words)………………..................... Inspection Request received on ………................................................ .......... 2) ……..

........... Description Qty. on …………… wherein the following materials were not found satisfactory as detailed below.....Annex XIV Format of Rejection Note by Independent Inspection Agency Name of Inspection Agency Manufacturers Name Person in charge Manufacturers address Dear Sir.... 2) …….......... Handpumps/ Spares Reference: 1) Purchase Order No…….. Yours faithfully...… Kindly refer to the visit of our representative for inspection at your works in . No....... Signature and Date CC to: Buyer/Customer 68 ..... the material is rejected and you are requested to replace/rectify and re-offer for inspection.................………………...................... Offered Reasons for Rejection Remarks Due to the above deviations......... Concerning: Inspection of .........

69 . 4 Spirit Level 0.Annex XV List of Measuring Tools required for Customer’s End Inspection No. length.1/m For checking level flanges at the time of installation 5 Elcometer 0 -100 micron For checking coating thickness 6 Magnet For checking material of Stainless Steel components Elcometer Magnet Measuring tape Sliding Calliper Steel ruler Spirit level Using a plug gauge E0016 for checking the pump cylinder against transport damage. Name of Equipment Requirement 1 Measuring tape 3m For measurement of length and height 2 Steel ruler 250 / 300 mm For measurement of length and height 3 Sliding Calliper 250 / 300 mm For measurement of thickness. Ø etc. width. is recommended. This checking tool might be borrowed from the IIA or the pump manufacturer.

Table of dimensions. Fluid systems .Product grades A and B. tolerances. Sampling procedures for insp. Metallic coatings . Structural steels.Sealing devices . Specification for general purpose acrylonitrile . Hexagon head screws . cross-sections. Thermoplastic pipes .Product grade A. Chromate conversion coatings on electro plated zinc and cadmium coatings. Unplasticized compounds of vinyl chloride (PVC-U) – Designation. Pipes and fittings (of PVC-U) for water supply – Specifications .Hot dip galvanized coatings . Adhesives with solvents for assembly of PVC pipes – Basic test methods.Product grades A and B.Electroplated coatings of cadmium on iron or steel. Other References: No. Plain end steel tubes. Plain washers .Requirements. Welded steel tubes for pressure purposes . gaz-shielded welding and gaz welding – Joint preparations.Sealing devices .Electroplated coatings of zinc on iron or steel.Product grades A and B. Steel tubes for water and sewage.General. Metallic coatings . Plastics – Polyamide (PA) moulding and extrusion materials.Pipes / Sockets.Quality acceptance criteria.Universal wall thickness table.O-rings .O-rings . Cold finished steel – Dimensions and sectional properties. Thermoplastic pipes for the conveyance of fluids – Dimensions and tolerances. Pipes and fittings (of PVC-U) for water supply – Specifications . welded and seamless . Wrought copper-zinc alloys – Leaded copper-zinc alloy.butadiene rubbers. by attributes – Sampling plans indexed by AQL. Plastics – POM moulding and extrusion materials – Designation. Hexagon nuts. Hexagon head bolts . Stainless steel tubes – Dimensions. Parallel pins. Metallic coatings . Stainless steels – Chemical composition. Fluid systems . Rubber . Title 70 Publisher Year of Publication 1 Afridev Handpump Specification SKAT-RWSN Revision 5-2007 2 Afridev Injection Moulding Manual SKAT-RWSN Revision 1-1999 3 Moulding Guidelines for Rubber Components SKAT-RWSN Revision 1-1999 4 Afridev Installation and Maintenance Manual SKAT-RWSN Revision 2-2007 5 Afridev Mould Drawings for Rubber Components SKAT-RWSN Edition 2003 6 Afridev Quality Control Guidelines SKAT-RWSN Revision 2-2008 .Tolerances for products.Annex XVI Reference Standards used for Afridev Handpump Manufacturing ISO 426-1 ISO 426-2 ISO 559 ISO 630 ISO 1127 ISO 1163-1 ISO 1461 ISO 1874-1 ISO 2081 ISO 2082 ISO 2338 ISO 2859-1 ISO 3302-1 ISO 3601-1 ISO 3601-3 ISO 4014 ISO 4017 ISO 4019 ISO 4032 ISO 4065 ISO 4200 ISO 4422-1 ISO 4422-2 ISO 4520 ISO 7089 ISO 7387-1 ISO 9330-1 ISO 9692-1 ISO 9988-1 ISO 11922-1 ISO 15510 BS 2751 Wrought copper-zinc alloys – Non leaded and special copper-zinc alloy. tolerances. Metal-arc welding.ID.Technical delivery conditions. unhardened. style 1 .Normal series .

Annex XVII Drawings of recommended Special Gauges & Templates for Afridev Drawing No.: Please see next page! 71 E0009 (Distance gauge) E0010 (Slot gauge) E0011 (Snap gauge) E0012 (Snap gauge) E0013 (Gap gauge) E0014 (Ring gauges) E0015 (Plug gauge) E0016 (Plug gauge) E0017 (Slot gauge) E0019 (Snap gauge) E0020 (Snap gauge) E0022 (Snap gauge) E0026 (Template) E0027 (Distance gauge) E0039 (Snap gauge) E0040 (Snap gauge) .

72 .

73 .

74 .

75 .

76 .

77 .

78 .

79 .

80 .

81 .

82 .

83 .

84 .

85 .

86 .

87 .