The CRGO (Cold Rolled Grain Oriented Silicon Steel and strip) is an extremely important material used in the production of transformers and other electrical equipment. This material is characterised by various properties, including high permeability, low core loss, and directional magnetic characteristics, which make it ideal for use in transformer cores where effective handling of magnetic flux is very important.
The quality and performance of these sheets are specified by different standards and certifications to ensure that they satisfy the necessary electrical application requirements. An example of such a vital standard is IS 3024:2015, which provides grain-oriented electrical steel sheets and strips.
As per IS 3024:2015 in respect to CRGO steel, this blog outlines certification requirements. In this blog, we will consider what this standard is about, the key requirements found in the standard, the certification process, and the importance of the industry at large.
Understanding about CRGO Steel and Its Importance
The CRGO steel is an electrical steel that evolves favourable magnetic properties in the direction of rolling during processing at the manufacturing stage. The steel grains effectively minimise the loss of energy during the re-induction and de-induction of the magnetic cycles. This is considered important when the material is used for transformer applications, for which energy savings and performance are crucial.
The first and foremost application of CRGO steel is in transformers, especially power and distribution transformers. The cores in a transformer guide magnetic flux and ensure that energy conservation happens with the least loss possible. As energy losses cause inefficiency and demand more operational costs, the quality of CRGO steel directly influences efficiency in the transformer.
What is IS 3024:2015?
IS 3024:2015 is an Indian standard that lays down the stipulated requirements for CRGO steel. This ensures that the material used in building transformers and electrical devices meets the specified performance criteria. Key Aspects of IS 3024:2015:
Chemical Composition
The standard requires the composition of the steel, specifying limits for elements like silicon, carbon, and sulphur. These four materials influence the magnetic properties and performance of steels.
Magnetic Properties
This aspect specifies the minimum magnetic properties to be possessed by the steel. Its specific permeability, core loss, and magnetic induction required for efficient operation of the transformer are specified.
Mechanical Properties
The standard also comprises requirements for the mechanical properties of the steel, including tensile strength and elongation, which ensures that the material used can bear the mechanical stresses endured during manufacturing and operation.
Dimensional Tolerances
Accurate dimensional tolerances are important for precisely assembling the transformer cores. The standard specifies the acceptable limits of tolerance for the thickness, width, and flatness of the steel sheets and strips.
Certification Process for CRGO Steel according to IS 3024:2015
The process of certification by BIS undergoes some steps, all of which are intended to verify that the product meets the required standards. Therefore, here is a step-by-step guide to the certification process for CRGO steel as per IS 3024:2015:
STEP 1: Submission of Application & Preliminary Evaluation
The certification process starts when the manufacturer submits their application to BIS. The BIS will then start with an initial assessment of the manufacturer’s facility and production processes. During this phase. The manufacturing processes, quality control system adopted by the facility and material traceability are assessed.
STEP 2: Sample Testing
After the initial evaluation, the CRGO steel test samples are taken for testing. Several tests are carried out on the test samples in order to verify whether they conform with the standards under IS 3024:2015. Usually, these samples are subjected to a number of tests, such as:
- Chemical Analysis: In this method, one determines if the steel composition does or does not exceed certain limits.
- Magnetic Testing: Magnetic testing measures the ability of steel to comply with the required standards with respect to core loss and permeability.
- Mechanical Testing: Under this test, the tensile strength and elongation are the properties, which are being verified.
- Dimensional Inspection: Dimensional observation of samples is used to check that they are within acceptable tolerances.
STEP 3. Documentation Review
Besides testing, BIS will examine the documents provided by the manufacturer. Some of the essential documents from the list of documents needed include the following:
- Material Test Reports: The documented results of the tests conducted on the steels, including chemical, mechanical, and magnetic properties, need to be submitted.
- Quality Control Records: The manufacturer’s quality control documents are scrutinised in order to ensure that they have continuously checked the quality of the CRGO steel while under process.
- Traceability Documentation: The documentation related to material traceability is checked to trace back the steel to its origin.
STEP 4: Grant of Certification
After the result of proper testing and scrutiny of documentation, BIS decides upon whether to issue or reject the certificate. If the CRGO steel meets all requirements stipulated under IS 3024:2015, the manufacturer shall receive a Certificate of Conformity. The certificate confirms compliance, showing that the material is suitable for electrical applications under this standard.
STEP 5: Surveillance and Recertification
It is not a one-time certification process. Manufacturers will be subjected to surveillance audits at regular intervals and should also proceed with re-certification to ensure continued compliance with IS 3024:2015. In surveillance, the BIS shall conduct the following activities:
- They will conduct Follow-up Inspections to check conformance with the IS 3024:2015 standard.
- They will take new samples of CRGO steel to get them tested and confirm the material’s conformance to the required specifications.
- BIS will review the updated documents provided by the manufacturer to ensure that quality control systems and traceability procedures are still in place.
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List of Tests for the Certification Process for CRGO Steel
Several tests required while acquiring the certificate for Cold Rolled Grain Oriented (CRGO Steel) & Strip are as follows:
- Test of chemical analysis
- Test of mechanical properties
- Test of magnetic properties
- Core loss Testing
- Dimensional inspection
- Coating mass testing
- Tensile testing
- Bend test
- Surface insulation resistance test
- High-frequency core loss test
Key Documents to Obtain Certification for CRGO Steel
To acquire ISI or BIS Certification for Cold Rolled Grain Oriented (CRGO Steel), you will have to submit certain essential documents. The list of documents is as follows:
First Application Form V
This form will contain the primary factory and information related to the product category.
ISI/BIS Application fee
A copy of Remittance/Payment Advice.
Test Report
A Copy of a test report done within a month by the Internal Laboratory indicating product compliance with the relevant Indian Standard.
Address Proof
Address Proof of Factory units (Factory license or Tax Registration document in the name of the manufacturer showing their scope)
Trademark Registration
Trademark Registration, if available (Photocopy of Trademark Registration)
Certificate from Regulatory Agency
Certificates from the concerned regulatory agencies for manufacturing.
Product Drawing
Product Drawing (as applicable) of the current manufacturing capacity.
Details of Raw Materials
The details of the Raw Materials will include the names of the components, the names of the suppliers, and the quality certificate of each component.
Details of Machine
The details of the machine will include its name, the names of the manufacturers, its manufacturing capacity, and the quantities.
What is the Importance of Certification for CRGO Steel?
Fundamentally, the certification, according to IS 3024:2015, is considered important in ensuring the quality and performance of CRGO steel concerning matters dealing with electricity. The importance of certification for CRGO Steel is as follows:
Ensuring Consistency in Quality
This certification assures that the CRGO steel continuously conforms to the stringent requirements necessary for use in electrical applications. Transformers and other electrical devices depend on consistency in quality to operate reliably. Any variation from the necessary requirements can result in inefficiencies, higher operating costs, or even equipment failure.
Improved Safety and Reliability
A steady supply of electricity depends on the reliable operation of the transformers, which are vital parts of power distribution systems. Certification of the CRGO steel gives confidence that the materials used for these transformers are of the finest quality, ensuring high levels of safety and improving the reliability associated with the entire configuration of power networks.
Facilitating Market Access
To enter the Indian market, producers of CRGO steel must have certification, which should be in accordance with IS 3024:2015. Most Transformer Manufacturers consider IS 3024:2015 a mandatory criterion for the supply of materials since it shows conformance with the required standards for use in the Electrical Infrastructure of India.
Building Trust with Customers
Customers such as transformer manufacturers or utility companies can feel reassured by the certification that the CRGO steel they are buying meets the required performance and quality standards. It builds trust in the material in use, reducing the possibility of disputes and strengthening long-term commercial partnerships.
Support Energy Efficiency Programs
Energy efficiency goals are closely related to transformer efficiency, given their role in energy transmission and distribution. Certification of CRGO steel contributes to minimising energy losses to support wider objectives aimed at improving energy efficiency and reducing environmental impact.
In order to match pace with the energy efficiency standards, manufacturers and importers of CRGO steel must get their BEE registration done.
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Challenges in Obtaining Certification for CRGO Steel
While certification is very important, this does not come without a challenge. There are some challenges or issues that the manufacturers may encounter while complying with IS 3024:2015. Some of the challenges faced by them are as follows:
1. Meeting Strict Requirements
IS 3024:2015 has very strict demands, and tendering to such specifications is not easy, especially among CRGO steel manufacturers who are still new to the industry. Often, significant investment in technology and expertise is required to achieve the necessary chemical composition, magnetic properties, and mechanical characteristics.
2. Ensuring Continuous Compliance
Complying with the standard on an ongoing basis is also necessary for maintaining certification status; hence, manufacturers require strong quality control systems. For some small-scale producers, this could be very costly as they find it hard to allocate the resources needed for continuing surveillance and re-certification.
3. Navigating the Process of Certification
The certification process itself can be quite complex, involving many different steps, starting with application submission and preliminary evaluation, testing, documentation review, and ongoing surveillance.
The process may pose some difficulties to the manufacturers, especially given that they may have little or no clue regarding what is expected of them and the process they have to follow.
Conclusion
In brief, the certification of CRGO steel in accordance with IS 3024:2015 aims to meet stringent standards of quality aspects and performance of the electrical appliances used in the transformers. Even though it is quite a difficult process, the investment in this is worth every penny since it comes with various benefits, such as consistent quality, better safety, access to markets, and support for energy efficiency, making it an indispensable prospect for the manufacturer.
In addition to this, acquiring this certification will lead to performance reliability and give manufacturers confidence in a highly competitive electrical materials market. Ensure your CRGO Steel meets the highest standards! Get BIS Certification for CRGO Steel by visiting our website Corpbiz and secure your certification with ease.
Frequently Asked Questions (FAQs)
What is the purpose of a Cold Rolled Grain-oriented Electrical Steel (CRGO)?
CRGO steel is mainly used in the production of transformers and other electrical machinery. It is perfect for transformer cores due to its high permeability, low core loss, and directional magnetic properties, guaranteeing efficient handling of magnetic flux with less energy loss.
What is covered by the IS 3024:2015 standard?
The specifications for Grain-Oriented electrical steel sheets and strips are outlined in the Indian standard IS 3024:2015. To ensure that CRGO steel meets the performance requirements for use in transformers and electrical devices, it covers aspects such as chemical composition, mechanical properties, magnetic properties, and dimensional tolerances.
What is the certification process in the CRGO steel?
There are multiple steps in the certification process:
Application submission and initial assessment of the manufacturing plant.
Examining CRGO steel samples to make sure they meet the requirements.
Examining quality control documents and material test results, among other important documents.
Granting Certificate for the CRGO steel upon fulfilment of all specifications.
Continuous monitoring and re-certification to guarantee consistent adherence.Why is CRGO steel certification important?
Certification guarantees that CRGO steel continuously complies with electrical applications' performance and quality requirements. It enhances consumer trust, opens up new markets, and increases safety, reliability and energy efficiency, especially in the transformer manufacturing sector.
What obstacles manufacturers face during BIS certification?
Complying with the stringent standards requirements, maintaining continuous compliance with strong quality control systems, and navigating the intricate certification process are just a few of the hurdles which manufacturers may encounter and need to overcome. Moreover, the requisite technological, experience, and resource investments might pose a significant hurdle for new or small-scale businesses.
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