ea SRI FES fa — shar) ee PLANT STANDARD irep-uaripwar) {Page ' of & General Specification for Steel Castings with ID. NO. 4 Based on: TLV 0100 Sept. 2003, 1.0 SCOPE OF APPLICATION The specification governs the quality of steel castings with Identification number e.g barrel type casing, inner and outer casing, blade carrier, valve casing, inserts, etc 20 APPLICABLE REFERENCE DOCUMENTS EN 10213, SEW 110, EN 287, EN 1370,EN 1435, EN 12681,EN 444, ISO 8062, DIN 1683 part 1,DIN 1690 Part 2 (table-4), BNIF 369-01, MSS SP-55, EN 12517, EN 10204, HW 0880830 (PA 11.60), HY 0980829 (PA 11,61), ASTM A 370. |n case of differences or contradictions of the referenced documents the higher requirements shall be applied. Equivatent standards with prior permission are acceptable, 3.0 CONDITION OF DELIVERY The casting shali be supplied in the heat-treated and machined condition as per ordering drawings and specifications. 4.0 DIMENSION & TOLERANCES a fat Castings shall be supplied as per the drawing accompanying the order. The supplier u shail check the dimensional accuracy before giving inspection call to the purchaser and ae shall record the actual values on the order drawing, Tolerances: Unless otherwise stated in the order document, general tolerance as per DIN1683 Part-1, accuracy degree GTB19 is applicable. a GENERAL REQUIREMENTS ‘ g i E Before starting the production the supplier shall check the ordering drawing with respect. E to casting and inspection specific design. He shall outline his objectives regarding Bat Optimization of casting and inspection technology, and bring it into notice for agreement e with BHEL, Before starting the production the ‘supplier shall submit the following documentati~7 to the purchaser. - Amanufacturing and inspection sequence plan (MIP) establishing the quality assured ‘sequence of operations and a time schedule for the individual manufacturing steps. ya OBERS [EPse—|wrae Melba [ee TT aoe Tira WORKED SY eee Aya sa K Pawaaies eed” CHECKED! NAT PT ar — to ee cacao] ve Loateesenarune Aad ae SR ae Se Jomoveo PLANT STANDARDS COMMITTEE ea ares 7 a ware reenceo. MTE [ove stananos owvson} DATE:22.4-03HW 0980832 7S ‘I PLANT STANDARD _qrer-nariowar) [Page ? of © am Ruel Fees - eftar) - All welding procedure approval records (WPAR) according'to SEW 110, or an equivalent standard which are essential for the casting: - List of qualified welders according to EN 287 or other equivalent standard, {f joint welding is necessary, the supplier shall submit a welding plan for approval by BHEL before starting production. This also applies for repeated orders with the same joint weldings. 6.0 MANUFACTURING 61 General Manufacturing as per EN 10213 Inner iron chills and chaplets which remain in the casting are not acceptable. 62 Wel 9 Welding shall be performed on heat treated castings only according to the successful welding procedure approval record (WPAR). Area to be welded shall be ground down to the flawless base metal and design welds shall be prepared accordingly. This shall be checked by surface crack inspection. In this case quality level S1 according to HWW 0980823 (Based on PA 11.61) shall be achieved. In case of design welding, the weld ends have to fulfil severity level 1 in UT as per HW (0980830 (PA 11.60) over a length of 50mm, COPYRIGHT AND CONFIDENTIAL Before welding, the supplier shall hand over to BHEL a documentation of the areas -— prepared for welding and the welding procedure specification (for information only) ot Additionally, he supplier shall submit 2 welding pian, if this has not already been done. ie ft The excavations ready for welding with a length >150 mm or with a depth > 25mm or E a i 240% of the wall thickness shall be documented by a sketch or a photograph noting the i t appropriate positions and dimensions so that their traceability is assured. tE cE Excavations which causes wall puncture shall be additionally marked in the record of areas t prepared for welding. Any bulld-up welding greater than 100 cm? shall be ae documented Several non-recordable production weldings shall be treated as one welding, if E t E their distance to each other is smaller than the length of the biggest excavation of them, E TE At unusual large production welding (e.g. weight of filler > 3% of the total casting weight) EE and / or if large welding is situated in the high stress areas of the casting, the purchaser E i reserves the right to request a further quality heat treatment after welding. Production welds without post weld heat treatment are not acceptable. | S| 7.0 Properties and Tests edie i ae 7.4 Mechanical Properties Revo - Rave 3] 00 worssoay | SS 12% i ER S$-g Pus + | 4 a = ih cavenep oy AS~ IW 0980832 eet aes ia - star) 7S a PLANT STANDARD urer-uaripwar {Page 3 of 6 The mechanical properties shall be determined on cast-on test samples, which shall have effective dimensions of at least 70mm X 100mm X 250 mm after removal from casting, The keel block shall be located on the casting with the area 7OmmX250mm according to the Foundry Technology. Any filter between the casting and the test blocks is not permitted. For castings with nominal wall thickness < 40mm, it is also possible to use test coupons connected to the casting with a channel. The thickness of the wall of the casting having ‘steam and pressure is regarded as nominal wall thickness. Position and Identification of the test sample shall be documented by sketch or Photograph. The test samples shall be cast as far apart as possible from each other. The original position on the casting and the identification of each test block shall be documented in an appropriate manner including sketches or photos. Furthermore, it shall be documented from which test block the specimens for mechanical properties test were taken, The test samples must not be cut from the castings until after completion of the hardening cycle. The test samples may be parted off at the earliest during heating up for tempering, Prior to separation from the casting, these samples must be Identified by the authorized inspector. Every time the casting undergoes heat treatment, the test sample shall be heat treated as well The specimens for the determination of the mechanical properties shall be taken from the test sample as near as possible to the cutting face. The mechanical testing shall be performed on 4 test coupon for casting having a weight < 10,000 kg and on 2 test coupons for castings having a weight of > 10,000 kg. For castings, which will not be pressure loaded and are < 100 kg, test block can be cast separated from the casting as a batch test. The test samples shall be stored at the supplier's works for at least 6 months after release for shipping. Testing of the mechanical properties shall be performed in presence of the purchaser or his authorized representative. If the purchaser waives the final inspection, the mechanical Properties shal! be determined in presence of the manufacturer's authorized inspector. The tensile properties shall be performed according to EN 10002-1 on cylindrical Proportional specimens with a diameter d 2 10mm in the measuring length. Testing according to ASTM A370 using the “standard specimen’ is acceptable. 7.2 Outer and inner Quality /NDT 7.24 General The chemical composition of the melt shall meet the requirement of the alloy as per the specification attached with the purchase order. The heat analysis shall be performed on a ‘specimen taken from the pouring stream of the casting_eacerare ee At se ntrh bad gem efter enue a hive sa marie beam feet | 7.2.2 723 _ wivenet ses fu — ahem) HW 0980832 CTT som PLANT STANDARD izer-narmwary) [Page * of & {In case of a check analysis, the permissible deviations of the check analysis with respect to the specified heat analysis are defined in EN 10213-1. For efements specified in the alloy specific material specification but not listed in EN 10213-1 Table-B, maximum deviations of 10% of the specified heat analysis are acceptable. The basis of NDT are HW 0980830 (PA 11.60) for UT, HW 0980829 (PA 11 61) for MPUDPT and EN 12681 for RT (test class A according to EN 444). In case of quality class 1, €.g. weld-on ends, test class B according to EN 444 shall be met for RT.If class B can not be reached due to geometrical conditions, the requirements can be modified only after getting a written agreement from BHEL. The surfaces of the castings shall be clean and allow for visual inspection as per MSS SP-55. If NDT is performed, the surfaces shall be fit for testing e.g. ground. The Fequirements according to EN 1370 shall be fulfiled, min. 381 (at blast surfaces) or 3S2 (at ground surfaces) as per the French standard BNIF 359-01. ‘Scope of Inspection Following NDT shall be performed in delivery condition. RT can be performed before stress relieving: 2) Visual inspection of all external and internal surfaces. b) MPUDPT as per HW 0980829 (PA 11.64). ©) UT of the whole volume according to HW 0980830 (PA 11.60) 4d) additionally RT of severity level 1 areas with wall thickness < 15 mm as per EN 12681 (test class B according to EN 444) e) MPI and UT of all welded areas. In addition RT of all welded areas in areas where RT is required. ‘) Random hardness testing on at least two finishing welds is required. g) Hardness testing on each joint weld is required. In case of joint welds > DN 300, hardness tests on two spots on the circumference are required. f) Design welds shall be inspected as per HW 0980830 (PA 11.60) and HW 0980829 (PA11.61). RT according to EN 1436 is to be carried out in the case of wall thickness < 15 mm, Welds for covers of core locators and fettiing openings are not to be treated as design welds. Criteria for Registration and Decision a) Visual Inspection: Criteria of standard MSS SP-55 and EN 1370 shall be applied. b) MPUOPT: Irrespective of the standard specified on the drawing accompanying the order, the criteria of HW 0980829 (PA 11.61) is valid in any case, Regarding the severity levels, the values of the respective order drawing are valid. ccunexeD ayCory Wart FERS fia — sftaR) HW 0980832 PLANT STANDARD _ qiger- HARIDWAR) ‘erate Ga sierra ree genes econ pet acer nbs epee wf 8 deen 8.0 S © UT: Irrespective of the standard specified on the drawing accompanying the order, the criteria of HW 0980830 (PA 11.60) is valid in any case. Regarding the severity levels, the values of the respective order drawing are valid, ) If the order drawing does not include any reference regarding the severity level, then the minimum requirement is $2V2 for the entire casting and S1V1 for weld ends, 4d) RT: Severity level of standard DIN 1690-2, table-4 shall be applied. €) Inspection of design welds : Criteria according to HW 0980830(PA 11.60) for UT and HW 0980829 (PA 11.61) for MPVDPT and EN 12517 severity level 2 (RT) shall be applied MARKING The Suppliers identification no., drawing no. & material designation e.g. GX23CrMoV12- 1 are to be cast on the casting at the position specified in the order drawing. If the drawing does not specify any position for marking, the supplier shall merk the casting on his own, If the cast on identification no. is eliminated, e.g. due to necessary weld repairs, the marking shall be hard stamped using at least 12mm letters. The replication of the marking by shielded metal arc welding is not allowed. All further marking should be close to identification no. To avoid any accidental exchange, all specimens shall be hard stamped marked with the identification no and the specimen-no. before cutting off, TEST CERTIFICATES Unless otherwise specified, the supplier shall furnish 4 copies of test certificate 3.18 according to EN 10204 to BHEL pror to, but in no case later than the delivery of the casting. The test certificate shall contain the following: a. Identification no. and order no. on every page b. Material designation c. Name and drawing no. of the casting d. Melting method, heat no. and heat analysis. @. Photo or sketch of test coupon position f. Mechanical test result including hardness test. All individual values shall be reported. g. Complete information on all heat treatments performed in the real order. h. Photos or sketches with all areas prepared for welding i, Weld report with the information of the WPAR, the welders and the used electrodes. j, Confirmation of the quality levels achieved. k. NDT report \. Dimension report.: record of the actual dimensions on the order drawing m. Report of any other test specially agreed, P2508 [Porc10.0 HW 0980832 PLANT STANDARD quece-naripwar) DEVIATIONS ‘Any deviation from this delivery specification has to be reported to BHEL immediately using Performa PU-25 supplied with the order. Any deviation is generally accepted only if this has been approved by BHEL in a written form. 11.0 CLEARANCE FOR DELIVERY The clearance for dispatch is based on the total results of all tests performed considering the service stresses of the component. BHEL has the right to accept deviations of the specified values, if itis shown by individual judgment that the service properties are not 2 reduced, Zz The clearance does not release the manufacturer from the responsibility for hidden E defects that are detected at later stage of manufacturing. 3 12.0 PACKING & The casting shail be suitably packed in a condition. to withstand for an indefinite time 5 exposure to all climatic conditions without developing any external and internal defects. 2H The casting shall be properly protected from damage during transportation. Supplier i may use anti-corrosive paint HE 1707 (produced by Central Insulation Technology, Os. BHEL Bhopal) or Petrolatum (produced by Bharat Petroleum). The overseas supplier may | use Tectyle 506 produced by M/s Volvoline, Germany). a zi if i fi EB } i 53 be H i ii sy sy aqsl 2 J\e i Ol | oe Prison gu Rew tour 20. » je ccuBckeD oY