Bharat Heavy Electricals Limited (A Govt.

of India Undertaking)

Piping Centre, 80, G. N. Chetty Road, CHENNAI- 600 017

Phone: 91 (044) 28161245, Fax 044 28161 341 e-mail: prs@bhelmpc.co.in

REF: ENQ NO: 4101000043

DT: 30.04.2010

Sub: Procurement ofBW fittings.

Ref: Enquiry No:PC:4101000043 dt 30.04.2010

Please find the following tender documents for reference.

1. List of items and sample drawings.

2. TDC:TDG: 102:04.

Pre qualification is the criteria for consideration for other than BHEL approved vendors. After qualifying for registration, the new vendors may be considered for future requirements, in line with BHEL system and policy. Such vendors will not be considered for this enquiry.

This is a limited tender and only vendors who are contacted through e-mail/courier may submit their offers.

New vendors may download vendor registration forms from BHEL web site www.bhel.com and relevant data for formal registration.

Dy1bp;':e

BHEL I Piping Centre 80,GN Road, T.Nagar Chennai -600017 Ph: 044-28161243

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• I \ Wel~:d=~it:1:!ngs~~~ India~ Boiler Reg~~~tions~

1.0 CODES:-

The fittings shall meet Indian Boiler Regulations (IBR) and the following requirements in addition to the standards specified in the Purchase Order (PO).

TDG: 102 Rev 04 Date: 27.02.2009 Page: 1 of 4

2.0 RAW MATERIALS:-

a) All pipes used for fittings shall meet the respective specification. The test certificate shall be furnished.

b) All mother pipes used for fittings shall be subjected to a hydraulic test as per SA 530 or UT as per ASTM E 213 at the mill

c) All plates used for fittings shall be UT tested as per S1 of SA578 and acceptance norms shall be as per Level B of SA578

d) The raw material forging shall be ultrasonically tested as per SA 388 and the acceptance norm shall be as per 3.3.4 of ASME Sec VIII Div 2.

e) Steel for SA 182 F 11, F 12 &F22 if indigenously procured, to be from following manufacturers approved under IBR for creep resistant steels: i ) Alloy Steel Plant Durgapur, ii )Tata Iron & Steel company, Jamshedpur & iii) Mahindra Ugine Steel Company, Mumbai.

f) Carbon content of SA 234 WPB, WPC, SA 105 fittings shall be restricted to 0.25% max

3.0 PROCESS:-

a) Process of manufacture shall conform to applicable standards.

b) All fittings shall be of seamless unless otherwise specified in the purchase order.

c) In case of welded fittings, WPS,PQR & welder qualification shall be approved by BHEL - PC, prior to start of welding.

d) All fittings shall have smooth surfaces, workman like finish and free from loose scales and defects like laps, seams, folds, cracks, pitting etc .. Repair by welding is NOT permitted.

e) Dimensions shall be as per ASME 816.9 or 816.28,8utt Weld edges shall be as given in Purchase Order. The ends of reducers shall have a straight portion of Minimum 13mm.

f) Unless otherwise specified in the P.O SA 234 WP 11/12/22 fittings shall be supplied as per class1, SA 182 F11/12 shall be supplied as class 2, SA 182 F22 shall be of class 3 only.

4.0 HEAT TREATMENT:-

4.1 All fittings shall be heat treated as below.

SA 234 WP 8 - As per specification

SA 105, SA234 WP C - Normalised

SA234 WP111 WP12/ WP22 - Normalised & Tempered

SA182 F111 F12/ F22 - Normalised & Tempered

Stainless Steel :-

SA 182 F3041 316/3211 347 SA 403 WP304/ 316/ 321/ 347

- Solution annealed

- Solution annealed

4.2 Fittings confirming to SA 234 WP91 and SA182 F91shall be normalised at1040 t01070deg C (for wall thickness larger than 75 mm, accelerated cooling may be done to obtain a fully martensitic structure) and tempered at 760:t 10 deg C

5.0 TESTING: -

(a) All ferrous fittings shall be tested by MPI as per ASTM E-709 and SS fittings shall be

LPI tested as per AS E 165.

S. Jayakumar, Engg

P. Elangovan, QA

Approved by K. Vedaprasad, QC

K. Ganeshan, MPL ~J

•Bhar3t.~HeaViElectriCa-.·.IS~·.L·I' .. m .... it.e .. d .. '. Piping cenT.re~-Chen.r.'. a. i Technical Delivery Conditions Conditions for Butt

L Welded -:- Fittings a~ p~r India~_Boi~~_~~e~_l:llat!~_~~_.

TOG: 102 Rev. 04 Date: 27.02.2009 Page: 2 of 4

(b) One fitting of each specification, heat, heat treatment lot and size shall be subjected to Tension Test as per applicable standard.

(c) All fittings of wall thickness above 6mm or NB 200mm and above shall be Ultrasonically Tested as per SA 388; acceptance norms shall be 3.3.4 of ASME section VIII Div.2.

(d) Hardness test shall be carried out on each fittings of WP91 I F91. For other fittings hardness shall be checked on 10% of the fittings.

(e) In case of welded fittings; all the welds shall be 100% RT tested and acceptance norms shall be UW 51 of ASME Sec VIII DIV-1

(f) The following supplementary tests shall be carried out for specifications namely SA105, SA 182 F11! F12! F22! F91, SA 234 WPC! WP111 WP12 / WP22 /WP91 ( No supplementary test applicable for SA 234 WPB )

a) Product analysis - one! heat! size.

b) Tension test - one / heat / heat treatment lot! size.

(g) Metallography:- Metallography shall be carried out on one per heat, per size, per heat treatment lot of WP91 / F91 fittings. Acceptance norms - The Material shall be free from any micro fissures. Microstructure shall show tempered martensite and also to be examined for any grain growth. Photomicrograph with 500x ( Min) magnification along with Metallography report to be provided. The actual magnification shall be indicated.

6.0 POSITIVE MATERIAL IDENTIFICATION ( PMI) FOR ALLOY STEEL FITTINGS.

Each alloy steel fitting shall be checked for the correctness of the material during manufacturing and final inspection using X-ray fluorescence principle or spark emission spectrography.

7.0 PAINTING, COLOUR CODING, MARKING, PACKING & END PROTECTION

7.1 PAINTING: All fittings (except stainless steel and galvanised) shall be painted on the external surface as given below

a) surface preparation: Blast cleaning

b) Primer coat: 50 microns of Red oxide zinc phosphate confirming to IS 12744

c) Final coat : 70 microns of Synthetic enamel paint confirming to IS2934 .

d) Shade: (i) smoke grey - shade no 692 of IS5 for all carbon steel fittings (ii) Sea green -- shade no 217 of IS5 for all Alloy steel fittings

The internal surface shall be protected with rust preventive coating or rust inhibitor. Stainless steel and Galvanised fittings need not be painted.

7.2 COLOUR CODING; All fittings shall be colour coded circumferentially at ends as

given below

P. Elangovan, QA

=

Red Blue

SA 234 WPB / WPBW WPC/ SA105

=

S. Jayakumar, Engg

Approved by

r-. K. Vedaprasad, QC ()"

K. Ganeshan, MPL '{

~'"

Bharat Heavy ElectricalsLim;ied~P;ping Centre-,ChEmnai Technical Delivery Conditions Conditions for Butt Welded - Fittings as per Indian Boiler Regulations.

I . . ~.~_ .. _ .... _. ... .._ ...

WP11 / SA 182 F11 = Green & White

WP121 SA182 F12 Black & Red

WP22 I SA 182 F22 ._ Blue & Red

WP91 I SA 182 F91 - Brown & Red

TOG: 102 Rev. 04 Date: 27.02.2009 Page: 3 of 4

SA 182 I SA 403 F I WP 304 316 321 347

=

Blue & Yellow Black & Green Blue & Brown Yellow & Black

=

=

=

7.3 MARKING:

7.3.1 The fittings dispatched to BHEL Stores shall be punched I etched with Material code, Heat number, material specification, maker's emblem, Inspectors seal and Statutory authorities seal (as applicable) .

In addition, the above details along with size shall be paint stenciled on the fittings.

If the thickness of the fitting is less than 6 mm, punching is not permitted and the above details shall be paint stenciled only. Fittings of size up to 2" (50mm) shall be tied together and the above details shall be punched / etched in a separate tag and tied to it

7.3.2 The fittings dispatched directly to project site as DTS shall be punched and paint stenciled with OU code (14 digit work order du detail) as given by purchase in addition to marking done as per para 7.3.1.

7.4 PACKING AND END PROTECTION: Machined ends of the fittings shall be well protected using end caps and fittings shall be suitably packed in box / crate to avoid transit & other damages.

8.0 INSPECTION & CERTIFICATION: -

, All fittings are to be Inspected at the manufacturer's works by the Inspection agencies / authorities as per IBR and as indicated in the P.O. Inspection certificate in IBR Form III C shall be submitted along with the Work Test Certificate countersigned by the above authorities and shall include the following.

1. Test Certificate Number & date.

2. BHEL P.O Number & Amendment Number

3. BHEL P.O. Serial Number

4. BHEL TOC Number

5. Size-wise Quantity

6. Specification, Grade & Year of code.

7. Heat/Melt Number

8. Starting material details.

9. Steel making process

10. Laddie Analysis of Raw Material and product analysis of fitting.

*11. Positive Material Identification (PMI) report for Alloy steel fittings.

*12. Supplementary Test(Product analysis, Tension test.) results.

*13. Heat Treatment Chart.

*14. NDE report. (VISUAL.MPI, LPI,UT)

*15. Tensile Test Report

*16. Hardness est Report

S. Jayakumar, Engg

Approved by

r-: K. Vedaprasad, QC

K. Ganeshan, MPLg(

P. Elangovan, QA

11'08 :f62Rev~04 I Date: 27.02.2009

I Page: 4 of 4

-~~---'---"

Bharat Heavy Electricals Limited, Piping Centre, Chennai

Technical Delivery Conditions Conditions for Butt Welded - Fittings as per Indian Boiler Regulations.

17. Metallography Report along with photomicrograph with 500x ( min)

magnification.

*18. Dimensional conformance.

*19. RT test report / Results (for welded fittings)

*20. Guarantee of HTP shall be given as follows> "Fittings are capable of withstanding without failure, leakage or impairment of their serviceability a hydrostatic test pressure equal to that prescribed for the specified matching pipe of equivalent material".

"Details furnished in the Tests certificate in lieu of chart/report is acceptable.

9.0 RECORDS OF REVISION :-

Rev 01 : a) Fully revised for better clarity. : b) Para 2.0 e added.

Rev 02 : a) Para 2.0 (c): UT acceptyance norms revised from level A to B. Rev 03 : a) Fully revised for better clarity.

: b) Para 4.2,6.0,8.0 (11) added.

c) Para 2 (d) ,4.1, 5 (d) are revised.

Rev 04: a) Para 5.0 (g), 7.0 and 8.0 (17) are revised.

*****

s. Jayakumar, Engg P. Elangovan, QA P-f~


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