Fire Extinguisher, Carbon Dioxide Type (Portable and Trolley Mounted) -Specification

IS 2878: Scope - Key Specifications and Tables

1. Nominal Sizes and Discharge Times (Clause 3.4, Table 1)

2. Mechanical Properties of Mild Steel Body (Clause 6.1.1, Table 4)

3. Mild Steel Body Weights and Dimensions (Clause 22.5, Table 1)

4. Materials of Construction (Clause 6.2.1, Table 2)

• Discharge valve: IS 3224 (squeeze grip valve)
• Safety device: IS 5903
• Syphon tube: Brass (IS 407 Alloy No. 2), Copper (

IS 2878 - Key References, Tables & Specifications

1. Materials of Construction (Clause 6.2.1, Table 2)

2. Body Weights & Sizes (Clause 22.5, Table 1 substitute)

3. Cast Alloy Chemical Composition (Clause 6.1.1, Table 3)

• Aluminum Alloys like 5283 A, 6061 A, 6082 A, etc.
• Key elements: Si, Fe, Cu, Mn, Mg, Cr, Ni, Zn with specified min-max %.

4. Water Compressibility K Factors (Clause 9.5.1, Table 6)

Notes:

• Safety devices must be in-built in

IS 2878 - Definitions: Key Tables & Specifications

While Clause 2.80 and Tables 3 & 4 are deleted, important data relevant to definitions and specifications include:

1. K Factors for Compressibility of Water (Clause 9.5.1)

Useful for calculating water compressibility in fire extinguishing systems.

2. Mild Steel Body Weights (Clause 22.5)

3. Class B Test Fire Tray Dimensions (Clause 9.5.4)

Summary

• **K

IS 2878 - Materials: Key Specifications and Tables

1. Mechanical Properties (Table 4, Clauses 6.1.1 & 6.2.2.3)

2. Materials of Construction (Table 2, Clause 6.2.1)

3. Aluminium Alloy Chemical Composition (Table 3, Clause 6.1.1)

IS 2878: Design & Construction Key Points

1. Body Weights & Sizes (Clause 22.5, Table 1)

2. Materials of Construction (Clause 6.2.1, Table 2)

Note: Metal horns not allowed for electrical fire rating.

3. Mechanical Properties (Clause 6.1.1, Table 4)

4. **

IS 2878 - Manufacturing and Heat Treatment Summary

Heat Treatment (Clause 6.2.2.3)

• Solution treatment: Heat at 515°C to 545°C
• Quenching: Water quench immediately after heating
• Artificial aging: Heat at 150°C to 200°C for specified time to achieve metallurgical changes

Mechanical Properties after Heat Treatment (Table 4)

Manufacturing Notes

• Heat treatment must be done in furnaces with accurate temperature control.
• Maintain temperature long enough for uniform metallurgical transformation.
• Materials conform to IS standards (e.g., IS 3224 for valves, IS 407 for brass).

Chemical Composition of Aluminum Alloys (Excerpt from Table 3)

Summary Diagram: Heat Treatment Process

flowchart LR
    A[Heat to 

IS 2878: Testing Requirements Summary

1. Frequency of Testing (Clause 6.1.1, Table B-2)

• Tensile & Bend Tests: One finished container per batch.
• After Material Cast Change: 3 containers from first 500 produced.
• After Production Break: 1 container from first 500 produced.
• Regular Intervals After First 500 Containers:

• All containers must be identifiable for traceability.

2. Hardness Test (Clause B-3)

• Brinell Hardness Test:
  • Load (kgf) / Ball diameter² (mm²) = 10
• Rockwell Hardness Test:
  • Values as specified in the standard must be met.
• Testing after heat treatment is mandatory.

3. Rounding Off (Clause None)

• Follow IS 2:1960 rules.
• Maintain significant figures as per specified values.

Additional Notes:

• Testing frequency can be increased for quality control.
• Failed container batches require isolation and retesting.

flowchart TD
    A[Start Production] --> B{Change in Material Cast?}
    B -- Yes --> C[Test 3 containers from first 500]
    B -- No --> D{Production Break?}
    D -- Yes --> E[Test 1 container from first 500]
    D -- No --> F[After first 500 containers]
    F --> G[Test containers based on daily production rate]
    G --> H[Identify & Trace Containers]
    H --> I{Test Passed?}
    I -- No --> J[Isolate & Retest Batch]
    I -- Yes --> K[Continue Production]

This covers key testing protocols per IS 2878 for container quality assurance.

IS 2878: Performance Requirements Summary

Mechanical Properties (Clause 6.1.1 & Table 4)

Paint Specification (Clause 8.4)

• Paint must comply with IS 2932.

General Performance Requirements (Clause 9 & 10.1)

• Components must meet mechanical strength, durability, and corrosion resistance as per IS 2878.
• Specific requirements for parts are detailed in Clause 10.2.

Notes:

• Bend test radius ensures ductility without cracking.
• Proof stress and tensile strength confirm material's load-bearing capacity.
• Hardness values ensure wear resistance.

flowchart LR
    A[Material] --> B[Tensile Strength ≥ 325 N/mm²]
    A --> C[Proof Stress ≥ 280 N/mm²]
    A --> D[Bend Radius ≤ 3 × tₐ]
    A --> E[Hardness ≥ 90 Brinell or 45 Rockwell B]
    F[Paint] --> G[Conform to IS 2932]
    B & C & D & E & G --> H[Performance Requirements Met]

This concise summary aligns with IS 2878's key performance criteria.

IS 2878: Marking and Labeling Key Points

1. Marking Requirements (Clause 10.2 & 8.3)

• Manufacturer's name or trade-mark
• Method of operation (prominent letters)
• The words "CARBON DIOXIDE TYPE" prominently displayed.
• Year of manufacture and date of refilling.
• Cylinder source, year of manufacture, and test pressure.

2. Fire Class Marking (Clause 8.3)

• Letters B and C indicate suitability for Class B and C fires (per IS 2190).
• Letter and shape sizes:

3. BIS Certification Mark (Clause 10.3)

• Use governed by BIS Act, 1986.
• License required for Standard Mark usage.

Summary Table for Marking on CO2 Extinguishers

flowchart TD
    A[Extinguisher] --> B[Mark Manufacturer Name]
    A --> C[Mark Operation Method]
    A --> D["CARBON DIOXIDE TYPE" Label]
    A --> E[Mark Fire Class (B & C)]
    E --> E1[Letter B in White, 2.5cm]
    E --> E2[Letter C in White, 2.5cm]
    A --> F[Year of Manufacture & Refill]
   

IS 2878: Packaging and Environmental Requirements Summary

1. Packaging Material Requirements (Clause 10.1.5)

• Packaging (excluding refills) must be recyclable, reusable, or biodegradable to minimize environmental impact.

2. Testing Frequency (Clause 6.1.1, Table B-2)

• Tests include tensile and bend tests on one finished container per batch.
• Additional tests after material changes or production breaks.
• Containers must be identified for traceability in case of test failure.

3. Hardness Testing (Clause B-3)

• After heat treatment, containers undergo:
  • Brinell Hardness Test: Load and ball diameter satisfy ( \text{Load} / (\text{Ball Diameter})^2 = 10 ) kgf/mm²
  • Rockwell Hardness Test: Values per design requirements.

4. Wall Thickness Calculation (Clause 2.48)

[ t = 2.48 \times V(D, IT) ]

Where:

• ( t ) = minimum wall thickness (mm)
• ( V(D, IT) ) = function related to internal pressure and dimensions
• ( P ) = test pressure (bar)
• ( D_o ) = external diameter (mm)
• ( D_i ) = internal diameter (mm)
• ( f_e = 0.75 \times Y ) (permissible equivalent stress, N/mm²)
• ( Y ) = 0.2% proof stress (N/mm²)
• ( T ) = tensile strength (N/mm²)

Refer to Table 2 in IS 2878 for material properties ( T ) and ( Y ).

flowchart LR
    A[Start Production] --> B{Material Change?}
    B -- Yes --> C[Test 3 containers

IS 2878: Sampling and Criteria for Conformity

Sampling (Clause 1.2.1 & 1.2.2 / Annex E)

• Samples are taken randomly from each lot.
• Sample size depends on lot size as per the table below:

Criteria for Conformity (Clause 1.2.4)

• All samples tested must pass all specified tests for the entire lot to be accepted.
• Failure of any sample means the lot does not conform.

Additional Notes

• BIS Certification Marking (Clause 10.3) can be applied if conformity is achieved.
• Details and conditions for the Standard Mark are regulated by BIS rules.

flowchart TD
    A[Lot of Items] --> B[Random Sampling]
    B --> C{Sample Size %}
    C -->|Up to 25| D[3% Samples]
    C -->|26 to 50| E[5% Samples]
    C -->|51 to 100| F[8% Samples]
    C -->|101 to 200| G[8% Samples]
    D & E & F & G --> H[Test Samples]
    H --> I{All Tests Passed?}
    I -->|Yes| J[Lot Conforms]
    I -->|No| K[Lot Rejected]

Summary: Use the above sampling percentages, test all samples rigorously, and only accept the lot if all samples pass.

Inspection and Test Requirements for Aluminium Cylinders (IS 2878 - Clause 9.4 & Annexes)

Key Tests & Specifications:

• Tensile Test (Annex B-4):

  • Specimen: Longitudinal strip or test ring.
  • Cross-section: Wall portion or circular (≥7 mm diameter).
  • Surface: As manufactured, no machining except ends for gripping.
  • Cold bend test: Bend inward around radius ≤ 3× thickness without cracking.

• Thickness & Surface Defects (Annex B-6):

  • Check min. thickness by mechanical/ultrasonic methods.
  • Defects >5% thickness must be dressed; thickness after dressing ≥ minimum design thickness.

• Neck Folds (Annex B-7):

  • Inspect with introscope.
  • Visible folds removed by machining; thickness after machining ≥ 2× design thickness.
  • Re-inspect post-machining; reject if cracks or folds remain.

• Hydraulic Test (Annex B-8):

  • Each cylinder subjected to hydraulic pressure test.

Design & Test Pressures (Clause 1.5 & 6.2.2.2 f):

Other Inspection Criteria (Clause 6.2.2.2):

• Circularity tolerance: ≤1% difference in external diameter.
• Surface defects: No defect >5% shell thickness.
• Thickness: ≥ minimum calculated + agreed corrosion allowance.
• Mass & water capacity as per agreement.

flowchart TD
    A[Cylinder Manufacture] --> B[Thickness & Surface Inspection]
    B --> C{Defects > 5% thickness?}
    C -- Yes --> D[Defect Dressing]
    D --> E[Thickness Check]
    C -- No --> E
    E --> F[Neck Fold Inspection]
    F --> G{Visible Folds?}
    G -- Yes --> H[Machining & Re-inspection]
    G -- No --> I[Tensile & Bend Tests]
    I --> J[Hydraulic Test]
    J --> K[Final Approval]
``

IS 2878: Mechanical Testing Procedures - Key Points

1. Mechanical Properties (Table 4, Clauses 6.1.1 & 6.2.2.3)

2. Frequency of Testing (Clause 6.1.1, Table B-2)

• One finished container per batch minimum.
• After material change: 3 containers from first 500.
• After production break: 1 container from first 500.
• Regular intervals after first 500 containers based on daily production:

3. Hardness Test (Clause B-3)

• Brinell Hardness Test:
  Load (kgf) / (Ball diameter mm)² = 10
• Rockwell Hardness Test: Values as per requirement (≥ 45 Rockwell B).

4. Test Pressure Design (Clause 22.5)

Summary Diagram: Testing Flow

flowchart TD
    A[Start Production] --> B{Material Change?}
    B -- Yes --> C[Take 3 containers from first 500]
    B -- No --> D{

IS 2878 Volumetric Expansion Testing Summary

Key Specifications:

• Permanent volumetric expansion ≤ 5% of total volumetric expansion.
  [ \text{Permanent Expansion %} = \frac{\text{Permanent Expansion}}{\text{Total Expansion}} \times 100 \leq 5% ]

Test Methods:

1. Water Jacket Volumetric Expansion Test (Fixed Burette Method)
2. Water Jacket Volumetric Expansion Test (Levelling Burette Method)

Procedure Highlights (Both Methods):

• Fill container and jacket with water; bleed air.
• Set burette water level to zero.
• Pressurize container to 2/3 test pressure, check for leaks.
• Increase pressure to full test pressure.
• Record total volumetric expansion from burette reading.
• Release pressure, record permanent volumetric expansion.
• Verify permanent expansion ≤ 5% total expansion.

Important Notes:

• Rising water level during pressurization indicates leak between container and jacket.
• Falling water level indicates leak between jacket and atmosphere.

Formula Recap:

Diagram (Conceptual):

flowchart TD
    A[Fill container with water] --> B[Seal container in water jacket]
    B --> C[Fill jacket, bleed air]
    C --> D[Set burette water level to zero]
    D --> E[Pressurize container to 2/3 test pressure]
    E --> F[Check for leaks via water level stability]
    F --> G[Increase to full test pressure]
    G --> H[Record total volumetric expansion]
    H --> I[Release pressure]
    I --> J[Record permanent volumetric expansion]
    J --> K[Check permanent expansion ≤ 5% total expansion]

This ensures container integrity under pressure per IS 2878.

IS 2878: Ultrasonic Thickness Measurement Key Points

Ultrasonic Thickness Measurement (Annex D, Clause 8.1)

• Purpose: Measure thickness of seamless containers using pulse echo or resonance ultrasonic methods.
• Techniques: Contact or immersion.
• Test Areas:
  • Base end
  • Parallel body
  • Areas with surface blemishes removed by grinding or machining
• Surface Condition: Both test and reflecting surfaces must be clean.
• Equipment:
  • Frequency ≥ 2 MHz (Clause 2.2)
  • Coupling method ensures adequate ultrasonic energy transmission (Clause 2.1)
• Scanning: Relative rotation and translation to produce helical scans with ±10% pitch tolerance, ensuring 100% coverage.

Key Formula for Minimum Wall Thickness (Clause 2.48)

[ t = 2.48 \times V(D, IT) ]

Where:

• ( t ) = minimum wall thickness (mm)
• ( P ) = test pressure (bar)
• ( D_o ) = external diameter (mm)
• ( D_i ) = internal diameter (mm)
• ( f_e = 0.75 \times Y ) (N/mm²), max permissible equivalent stress at test pressure
• ( Y ) = minimum specified 0.2% proof stress (N/mm²)
• ( T ) = minimum tensile strength (N/mm²)

Notes on Material Properties (Table 2 in IS 2878)

flowchart LR
    A[Ultrasonic Thickness Measurement] --> B[Pulse Echo or Resonance]
    B --> C[Contact or Immersion Technique]
    C --> D[Scan Base End, Parallel Body, Ground Areas]
    D --> E[Ensure Clean Surfaces]
    E --> F[Frequency ≥ 2 MHz]
    F --> G[Helical Scan with ±10% Pitch]

Summary: Use ≥2 MHz ultrasonic equipment with proper coupling, scan all critical areas helically for 100% coverage, and verify thickness

IS 2878: Sampling and Conformity Criteria Summary

Sampling (Clause 1.2.2 / Annex E-1.2.2)

Samples are taken randomly from each lot based on lot size:

• For example, a lot of 100 items requires 8 samples.

Conformity Criteria (Clause 1.2.4)

• All tested samples must pass all specified tests for the lot to be accepted.
• If any sample fails, the lot is rejected.

Additional Notes

• BIS Certification marking is governed under BIS Act 1986 (Clause 10.3).
• Detailed sampling and conformity criteria are provided in Annex E of IS 2878.

flowchart TD
    A[Lot Received] --> B[Random Sampling]
    B --> C{Number of Items in Lot}
    C -->|Up to 25| D[Sample 3%]
    C -->|26 to 50| E[Sample 5%]
    C -->|51 to 100| F[Sample 8%]
    C -->|101 to 200| G[Sample 8%]
    D --> H[Testing Samples]
    E --> H
    F --> H
    G --> H
    H --> I{All Samples Pass?}
    I -->|Yes| J[Lot Accepted]
    I -->|No| K[Lot Rejected]

This ensures quality control by statistically verifying representative samples from production lots.