plug cocks for water supply purposes

IS 3004: Scope & Key Specifications Summary

Scope (Clause 2.0)

• Defines terminology and applicability for plug cocks used in waterworks.
• Covers dimensions, components, and design profiles per ISO metric screw threads.

Key Tables & Dimensions (Clause 7.5 & Table 7.1)

• All dimensions in millimeters.
• Washers conform to Table 1 dimensions (Clause 7.6).

Notes:

• Ends (Clause 3.1.1) are customizable per agreement.
• Threads follow ISO metric screw threads standards.

Visual: Component Parts of Plug Cock

graph LR
A[Body] --> B[Waterway]
B --> C[Plug]
A --> D[Ends (Custom)]
A --> E[Bolts & Nuts]
E --> F[Washers]

This outlines the main components and their relation per IS 3004.

IS 3004: Key Definitions & Tables for Plug Cocks

Clause 2.0: Definitions

• This clause specifies terminology used throughout the standard for clarity and uniformity.
• Examples include terms like Waterway, Washer, Ends, and Lead.

Clause 7.5: Waterway Dimensions (Table 7.1)

• Defines critical dimensions of the plug cock waterway in millimeters.
• Key parameters include:
  • Diameter sizes (15, 20, 25 mm)
  • Thread size (e.g., M12 × 1.5, M16 × 1.5)
  • Various dimensional values (e.g., 72, 75, 80 mm for length parameters)

Clause 7.6: Washer Dimensions (Table 1)

• Specifies washer sizes matching plug cock components.
• Washers must conform to the dimensions in Table 1 for proper fit and sealing.

Clause 3.1.1: Ends Specification

• Ends (types b, d, e) are to be mutually agreed between manufacturer and purchaser.
• Ensures compatibility with piping systems.

Additional Notes:

• Threads follow ISO metric screw thread standards (Part I).
• Dimensions are critical for interchangeability and pressure integrity.

flowchart LR
    A[Plug Cock] --> B[Waterway Dimensions]
    A --> C[Washer Dimensions]
    A --> D[Ends Specification]
    B --> E[Table 7.1: Sizes & Threads]
    C --> F[Table 1: Washer Sizes]
    D --> G[Agreement Manufacturer-Purchaser]

Summary: IS 3004 defines plug cock components

IS 3004: Types of End - Key Points & Specifications

1. Types of Ends (Clause 3.1.1)

• Ends for types (b), (d), and (e) are mutually agreed between manufacturer and purchaser.
• No fixed standard; customization allowed.

2. Plug Cock End (Clause 2.1)

• Plug cock has a taper seating with a rotatable plug controlling water flow.
• Plug retention: washer, screw, and nut at smaller end.

3. Screw Thread Dimensions (Notes 1 & 2)

• Use IS 4218 (Part VI)-1967 for:
  • P-nut dimensions (medium class tolerance)
  • R-bolt dimensions (medium class tolerance)
• Diameter range: 1 to 39 mm

4. Finish of Body Ends (Clause 7.5 & Table 7.1)

• Dimensions for waterway and ends (in mm):

Lengths may be adjusted for other end types.

Summary Diagram of Plug Cock End:

flowchart LR
    A[Body with Taper Seating] --> B[Rotatable Plug]
    B --> C[Port aligns with Body Ports]
    B --> D[Washer + Screw + Nut at smaller end]
    D --> E[Plug Retained]

For detailed dimensions, refer to Table 7.1 in Clause 7.5 and IS 4218 for thread specifications.

IS 3004: Nominal Size Key Details

1. Nominal Size Definition (Clause 4)

• Nominal size corresponds to the internal diameter or size designation of plug cocks.
• Ends are compatible with mild steel tubing per IS 1239 (Part I)-1973.

2. Key Dimensions (Clause 7.5, Table 7.1 excerpt)

• Waterway: Internal bore size for flow.
• Thread: ISO metric screw threads per IS 4218 (Part VI)-1967, medium class tolerance.
• Washer: Thickness as per Table 1 (Clause 7.6).

3. Thread Specifications

• ISO metric threads with medium tolerance as per IS 4218 (Part VI)-1967.
• Typical pitch: 1.5 mm for M12 and M16 bolts/nuts.

Summary Diagram: Nominal Size Components

flowchart LR
    A[Nominal Size] --> B[Waterway Diameter]
    A --> C[Length (L)]
    A --> D[Thread Size]
    A --> E[Washer Thickness]
    D --> F[IS 4218 Medium Tolerance]

For detailed dimensions and tolerances, refer to IS 3004 Table 7.1 and IS 4218 (Part VI)-1967 for screw threads.

IS 3004: Key Material Specifications & Tables

1. Material Requirements (Clause 3.1.2)

• Ends must comply with IS 1239 (Part I) - 1973 for mild steel tubing.
• Purchaser must specify detailed requirements to the supplier.

2. Nominal Size (Clause 2.0)

• Defines standard dimensions for pipes and components as per IS 3004.

3. Waterway Dimensions (Clause 7.5, Table 7.1)

• Dimensions in millimeters for waterway components.
• Sample from Table 7.1:

• Bolt sizes and thread pitches are standardized for assembly.

Summary:

• Use IS 1239 (Part I) for mild steel tube ends.
• Refer to Table 7.1 for waterway dimensions and bolt specifications.
• All dimensions are in mm.
• Ensure purchaser-supplier communication for specific material/end requirements.

flowchart TD
    A[Material Specified] --> B{Is tubing end required?}
    B -- Yes --> C[Comply with IS 1239 (Part I)]
    B -- No --> D[Standard Material]
    C --> E[Provide detailed requirements]
    D --> E
    E --> F[Use Table 7.1 for dimensions]
    F --> G[Select bolt size & thread pitch]

This ensures compliance with IS 3004 material and dimensional standards.

IS 3004: Manufacture and Workmanship - Key Points

1. Ends Specification (Clause 3.1.1):

   • Ends for types (b), (d), and (e) are mutually agreed between manufacturer and purchaser.

2. Material Quality (Clause 6.2):

   • Components must be sound, solid, free from laminations.
   • Surfaces should be smooth and well finished.
   • Non-machined parts must adhere to specified dimensional limits.

3. Dimensional Specifications (Clause 7.5 - Table 7.1):

   • Waterway and related dimensions (in mm) are standardized for different sizes (15, 20, 25).
   • Includes bolt sizes (e.g., M12 × 1.5, M16 × 1.5), thickness, and other critical dimensions.

4. Standard Mark Use (Clause 11.2.1):
   • Governed by BIS Act 1986.
   • License conditions available from BIS.

Summary Diagram: Manufacture & Workmanship Flow

flowchart TD
    A[Material Selection] --> B[Component Soundness Check]
    B --> C[Surface Finish & Dimensional Check]
    C --> D[Ends Specification Agreement]
    D --> E[Final Assembly & Standard Mark Licensing]

Note: Refer to Fig. 2 for standard end, tail pipe, and nut details to ensure conformity.

IS 3004: Construction and Dimensions (Clauses 7.4 - 7.6)

Key Specifications:

• Plug Cocks Dimensions (Clause 7.4): Refer to Table 1 and Fig. 1 for detailed dimensions; commercial machining tolerances apply.

• Waterway Dimensions (Clause 7.5):

  Size (mm)	A	B	C	D	E	F	G	H	I	J	K	L	Washer Thickness	Bolt Size	Thread Pitch	Nut Size	Nut Thread Pitch	Washer Diameter	Washer Thickness
  15	72	50	18	12	12	7.5	24	35	20	10	22	27	5	M12	1.5	20	M12	5	10
  20	75	68	22	20	20	11	29	40	25	10	25	33	5	M12	1.5	22	M12	6	12
  25	80	80	25	22	22	14.5	35	45	28	10	27	40	5	M16	1.5	25	M16	7	14

• Washer Dimensions (Clause 7.6): As per Table 1, matching bolt sizes and thickness for proper fit.

• Thread Standards: ISO metric screw threads per IS 4218 (Part VI) with medium tolerance class.

Notes:

• Bolt and nut sizes follow ISO metric standards.
• Lengths may be adjusted for different end types.
• Body ends finish per Clause 8 for sealing and fitting.

graph LR
A[Plug Cock Body] --> B[Waterway Dimensions]

IS 3004: Finish of Body Ends - Key Specifications

• Clause 3.1.1:
  Ends for types (b), (d), and (e) are to be agreed upon between manufacturer and purchaser—no fixed standard finish.

• Clause 6.3:
  All bodies, plugs, and components must be machine finished as per 6.3.1 and 6.3.2.

• Clause 6.3.1:

  • The taper of body and plug must be fine machine finished or precision ground.
  • The plug and body are lapped together to ensure full-area contact surfaces.
  • Contact surfaces of body, washer, and nut must be fine machined or precision ground, flat, and square to the plug axis.

Summary Table of Finish Requirements

This ensures proper sealing and mechanical fit in pressure parts, critical for valve and fitting performance.

IS 3004: Cleaning and Lubrication (Clause 9.1)

• Cleaning: All valve parts must be thoroughly cleaned to remove debris and contaminants.
• Lubrication: Apply a minimum quantity of lubricant on the seating surfaces of the body and plug to ensure smooth operation without excess that can attract dirt.

Key Specifications for Cleaning & Lubrication:

Related Dimensional Table (Clause 7.5, Table 7.1 excerpt):

Summary Diagram:

flowchart LR
    A[Cleaning] --> B[Remove all debris]
    B --> C[Lubrication]
    C --> D[Apply minimum lubricant]
    D --> E[On seating surfaces]
    E --> F[Smooth operation ensured]

Note: Use lubricants compatible with valve materials and operating conditions to avoid degradation or contamination.

IS 3004: Hydraulic Test for Plug Cocks

Key Specifications (Clause 10.1)

• Test Pressures:
  • Body test: ≥ 2 MPa (20 bar)
  • Seat test: ≥ 1 MPa (10 bar)
• Duration: Maintain pressure for at least 2 minutes
• Acceptance: No leakage or sweating during the test

Procedure Highlights

• Clean all parts thoroughly (Clause 9.1)
• Apply minimal lubricant on seating surfaces for smooth operation

Relevant Dimensions (Clause 7.5, Table 7.1 excerpt)

Summary Diagram of Hydraulic Test Setup

flowchart LR
    A[Plug Cock Assembly] --> B[Hydraulic Pressure Source]
    B --> C[Pressure Gauge]
    C --> D[Test Chamber]
    D --> E{Pressure Maintained for 2 min?}
    E -- Yes --> F[Check for Leakage]
    F -- No Leakage --> G[Test Passed]
    F -- Leakage --> H[Test Failed]
    E -- No --> I[Continue Test]

Note: Refer to Fig. 1 and Table I (Clause 7.4) for detailed dimensional tolerances and plug cock geometry.

IS 3004: Marking and Certification Summary

1. BIS Certification Marking (Clause 11.2 & 11.2.1)

• Standard Mark usage is governed by the Bureau of Indian Standards Act, 1986.
• Manufacturers must obtain a licence from BIS to use the Standard Mark.
• Details on conditions and licensing are available from BIS directly.

2. Key Dimensions Table for Waterway (Clause 7.5, Table 7.1 excerpt)

All dimensions in millimeters.

Notes:

• Refer to Fig. 2 of IS 3004 for standard end, tail pipe, and nut details.
• The Standard Mark ensures product conformity to IS 3004 specifications.
• Licensing and marking ensure traceability and quality assurance.

flowchart TD
    A[Manufacturer] -->|Applies for License| B[B