NPCIL Tube Fitting Specifications

NUCLEAR POWER CORPORATION OF INDIA LTD.
(A Govt. of India Enterprise)

SPECIFICATION NO. : PC-E- 274

TECHNICAL SPECIFICATION
ON
STAINLESS STEEL COMPRESSION TYPE TUBE FITTINGS.

REF. USI NO: 60614

REVISION NO. : 0
DATE OF ISSUE
(MONTH/YEAR)
: MAY, 2009
TOTAL NO. OF PAGES
(Including cover sheet &
Revision control sheet)
: 22

ORIGINAL

PREPARED BY: NARAYAN MANDAL, EE(C&I-PC)

A.S.N. IYER, DCE (C&I-PC)

CHECKED BY: CH. SRINIVASA RAO, ACE (C&I-PC)

REVIEWED BY: B.P. MAHESHWARI, CE (FHAC)

APPROVED BY: ANAND BEHRE, SO/H (C&I-PC)

(Name & Designation) (Signature) (Date)

(FOR REVISIONS - SEE REVISION CONTROL SHEET)

File Name: PC-E-274-R0.doc

REVISION CONTROL SHEET

DOCUMENT TYPE : TECHNICAL SPECIFICATION

NO. : PC-E-274 /Rev No. 0

TITLE : TECHNICAL SPECIFICATION ON
STAINLESS STEEL COMPRESSION TYPE TUBE
FITTINGS

REV. NO.
&
DATE
DESCRIPTION
OF
REVISION
REVISED BY
NAME &
SIGNATURE
CHECKED
BY NAME &
SIGNATURE
REVIEWED
BY NAME &
SIGNATURE
APPROVED
BY NAME &
SIGNATURE

ON
STAINLESS STEEL COMPRESSION TYPE TUBE FITTINGS

Page 1 of 20
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60614/PC-E-274 MAY, 2009

1.0 SCOPE :

This specification covers the general technical requirements for the design,
manufacture, inspection, testing and supply of stainless steel compression type
(flareless) tube fittings in Instrumentation applications.

2.0 CONTENTS

1.0 SCOPE
2.0 CONTENTS
3.0 APPLICABLE, STANDARDS, SPECIFICATIONS
& DRAWINGS
4.0 MATERIALS PROCESSES
& WORKMANSHIP
5.0 REQUIREMENTS
6.0 INSPECTION AND TESTING
7.0 DOCUMENTATION
8.0 IDENTIFICATION
9.0 PACKING & SHIPPING
ANNEXURE 1 SAMPLE QUALITY ASSURANCE PLAN
TABLE- I DIMENSIONAL TOLERANCES OF TUBE
FITTINGS
TABLE-II DIMENSIONAL TOLERANCES OF SS TUBES
3.0

APPLICABLE STANDARDS , SPECIFICATIONS & DRAWINGS :
All the specifications and standards listed below, of the issue in effect on the date
of the pertinent tendering documents, apply as specified herein. In the event of
any conflict between the provisions of this specification and the documents listed
below, this specification shall govern -

ANSI- B-1.1 Unified Inch screw threads (UN and UNR Thread
Form) equivalent for tube end.

ANSI-B.1.20.1 - Pipe threads, general purpose

ASME Boiler and - Section III, Division I, Sub-Section NB for
Pressure Vessel Code Class -I components

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60614/PC-E-274 MAY, 2009

ASTM-A-213 Standard Specification for Seamless ferritic &
austenitic alloy steel boiler super heater and heat
exchanger tubes.

SA-370 Specification for mechanical testing of steel product

ASTM-A-262 - Standard Practices for detecting susceptibility to
Inter granular attack in austenitic stainless steels

ASTM-A-276 - Standard Specification for Stainless Steel bars &
Shapes.
ASTM-A-314 - Standard Specification for Stainless steel billets and
bars for forging

ASTM-A-473 - Standard Specification for Stainless Steel Forgings

PP-M-107 - Technical specification for Seamless austenitic SS
tubing.

PP-P-198 - General Cleaning & handling requirements for
D2O/helium Services

SAE-J-514 - Hydraulic tube fittings

PB-P-541 - Methods and procedure for seismic qualification of
valves; panels devices; rotating and reciprocating
equipment; tanks, vessels, piping and supports.

PP-P-2014 - Procedure for ultrasonic examination of steel
forgings for general purpose.

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4.0 MATERIALS, PROCESSES & WORKMANSHIP :

4.1 Material, Processes And Parts

Materials, processes and standard parts shall be of good commercial quality and
in accordance with good practices pertinent to the manufacture of high quality
fittings for Nuclear Power Plants. All components of finished product shall have
material traceability

4.2 Workmanship

Workmanship shall be in accordance with high grade commercial practice
adequate to ensure satisfactory operation and service life. Fittings shall be free
from all burrs, loose scales and sliver which might become dislodged in usage
and all other defects which might affect their serviceability. All sealing surfaces
must be smooth to 0.8 microns(max).

No tool marks shall be permitted on the sealing surfaces. On the other surfaces
annular tool marks upto a maximum of 3 microns may be permitted.

5.0 REQUIREMENTS :

5.1 General

The tube fittings shall be capable of continuous satisfactory service over a period
of 40 years with minimum attention. Long term reliability under varying service
conditions is of prime importance and the use of high quality materials,
components, tools, equipments etc. in manufacturing and inspection of these
fittings is therefore required.

5.2 Material Requirements

Straight bodies, nuts and ferrules shall be from SS 316 conforming to ASTM-A-
276. Forgings shall conform to ASTM-A-314 & A-473. These fittings shall be
suitable for use on S.S. 304 L tubing conforming to ASTM-A-213 and NPCIL
specification PP-M-107, but with dimensional tolerances as per Table-II of this
specification.

5.3 Service Conditions

The fittings shall be suitable for the service under the following conditions -

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60614/PC-E-274 MAY, 2009

Process Fluid : D
2
O/Water, air, hydraulic oil, steam, nitrogen, and helium

Maximum working pressure of process fluid - 200 kg/cm
2
(g)

Maximum working temperature - 325
o
C

5.4 Design and Construction

The compression fittings are those which require no preparation of the ends of the
tube other than that they are cut square, and in which the joint is made by
compression of two ferrules, on to the outside wall of the tube. The design of
these fittings shall be such as to permit tube entry and fitting make up without
removal of the nut and ferrules. All components shall be of the same material as
the fitting body for thermal compatibility and corrosion resistance.

Abrupt reductions of sections shall be avoided. Sharp corners of inadequate
fillets, excessive under cuts or excessive grooves at the junction of small sections
with large sections of fittings shall be avoided.

Unless otherwise specified, each socket shall be provided with an internal
shoulder or stop against which the inserted tube cut square with its axis, shall
abut. Bore-through fittings will not have any internal shoulder.

5.5 Designation of Sizes of Fittings

The fittings shall be designated with the outer diameter of the tube with which
it is to be used.

5.6 Wall Thickness, Overall Dimensions and Pressure Rating

Unless otherwise specified the wall thickness and overall dimensions of fitting
shall conform to SAE-J-514. However, the wall thickness of assembled fitting at
any point shall not be less than thickness established by ASME-Section III, Sub-
Section NB for the required service conditions (pressure and temperature rating).

5.7 Dimensional Tolerances

Dimensional tolerances for the various components of fittings shall be such, that
interchangeability of components of same size of fittings is possible.

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60614/PC-E-274 MAY, 2009

The dimensional tolerances on Internal Diameter (ID)of nut, ferrules and body
are given in Table-I for reference.

These fittings shall be suitable for use with S.S. tubing conforming to ASTM-A-
213 and NPCIL specification PP-M-107. However these tube fittings shall be
suitable for use with tube hardness in the entire range of 65 RB to 80 RB. The
dimensional tolerances of SS tubes proposed to be used with these fittings, are
given in Table-II.

5.8 Hardness

Hardness of the body and nut shall be in the range of RB 70 to RB 90.

Pull out strength, leak tightness, assembly-re-assembly and other performance
requirements covered in Section 6.0 are generally achieved by maintaining proper
hardness values for front ferrule, back ferrules and at the tip portion of the back
ferrule (The ferrule hardness shall not be less than Rockwell-B-90).

Bidder shall justify, how these functional requirements are met in the offered
fittings, indicating hardness values for front ferrules, back ferrules and at the tip
portion of the back ferrule.

5.9 Screw Threads

All Taper Pipe Threads (NPT) shall be in accordance with ANSI B-1.20.1

Straight threads shall be unified screw threads conforming to Class 2A and 2B of
ANSI-B-1.1. Threads conforming to the other standards shall be subject to the
approval of the Purchaser. Silver coating on Nut threads shall be done to avoid
galling during assembly.

5.10 PERFORMANCE

5.10.1 General

These tube fittings must be capable of working with(without leakages or failure)
various fluids (including Helium)at low or high temperature, from vacuum to high
pressures. They should have sealing capacity to hold all fluids as well as gripping
capability to withstand axial, lateral and torsional forces met within industrial
tubing installations.

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60614/PC-E-274 MAY, 2009

All the parts of the fittings should be concentric and should be capable of self-
alignment when assembled with the tubing specified in PP-M-107 Fittings should
not create torque or leave residual strain on tubing. They should have enough
tube support ahead of the seal to resist any vibration. They should not weaken the
tube wall. They should not significantly reduce flow area. They should have a
residual spring condition so that temperature cycling will not cause leakage. The
design of the fittings should be such that they should not require any special tools
for assembly and disassembly of the fittings.

The tube fittings when assembled with the recommended tubes must be capable of
withstanding the following types of forces, in any possible combination :

a) Internal pressure & pressure cycling
b) Tension or axial pull
c) Compression or axial push
d) Torque or twist
e) Vibration.
f) Temperature variation

Any combination of all the above forces is possible.

5.11 Cleanliness

The fittings shall be free from any metal particles, contaminant and other forms of
dirt. Manufacturer shall follow the Purchasers instructions specified in PP-P-198
General Cleaning and Handling Requirements for Instruments and Fittings for
use in Heavy Water and Helium Services. Failure to meet this requirement shall
result either in rejection or clean-up of all the fittings at the discretion of the
Purchaser. Fittings in the made-up condition shall be suitably heat sealed in
polythene bags and shall be stored in clean storage. Manufacturer shall submit
detailed cleaning and packing procedures along with his bid.

5.12 Lubricants And Sealants

The manufacturer shall specify if any lubricants or sealants are required and give
details of availability, composition, method of use etc. These compounds shall be
Sulphur and halogen free.

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60614/PC-E-274 MAY, 2009

5.13 Installation Procedures

The manufacturer shall provide the recommended installation procedures and the
list of installation tools. A sample copy of the instruction manual shall be
submitted with the bid.

6.0 INSPECTION AND TESTING

6.1 General

The contractor shall be responsible for, and perform all the inspection and testing
specified herein in a manner satisfactory to and subject to the approval of the
Purchaser.

The manufacturer shall supply all the materials required for testing. He shall
prepare and arrange the necessary test pieces and provide the personnel and
equipments for such testing as may be carried out at his premises in accordance
with this Specification. In the absence of such facilities at his works for
conducting the tests, the manufacturer shall, at his own expense, arrange for the
tests to be carried out elsewhere.

The Purchaser or his authorized representative shall have access to the
Contractors and Sub-Contractors premises at all reasonable times to the extent
necessary to assess compliance with the provisions of this specification. The
Purchaser or his authorized representative shall be offered all reasonable facilities
to satisfy himself that the fittings are being manufactured in accordance with this
Specification.

The Purchaser shall also have the right to conduct at his own expense any
additional inspection or testing deemed necessary by him, to confirm the
compliance with the provisions of this specification.

6.2 Inspection

The fittings shall be inspected to determine conformance with all the provisions of
this Specification with respect to material, workmanship and cleanliness.

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6.3 Tests

6.3.1 General

The Contractor shall notify the Purchaser, the date and location of performing
the tests, giving sufficient notice to enable the Purchaser or his authorized
representative to be present.

The test procedure shall be proposed by the Contractor and approved by the
Purchaser. The contractor shall provide all the test equipments required.

The Purchaser or his authorized representative shall have access to the calibration
certificates of the test equipments used for these tests.

The random samples (around 50 nos.)required for prototype qualification tests
shall be selected by the Purchaser or his authorized representative from the bulk
lot and the samples selected for testing shall not form part of the bulk quantity to
be supplied against the purchase order.

Before performing the test the tube fitting samples shall be assembled with
appropriate S.S. 304 L tubing as per PP-M-107. While making the assembly the
recommended assembly procedure/steps shall be followed.

6.3.2 Prototype Qualification:

If called for in the tender/purchase order, the contractor will manufacture a
limited number of sample fittings of various types and sizes (about 200Nos.)as
prototype fittings and offer to the purchaser for their detailed evaluation. Out of
these, a few (about 50 Nos.)randomly selected fittings of different types and sizes
shall be subjected to all the tests mentioned in section 6.3.3. Subsequently
Prototype fittings of each size shall be subjected to seismic qualification test. The
fitting shall be assembled so as to give unsupported tube length of 0.5 metre and
the seismic vibration tested in accordance with NPCIL Specification PB-P-541,
such that the Test Response Spectrum (TRS) envelops the Required Response
Spectrum(RRS) .

During the test, the assembled fitting shall be internally pressurized to 200
kg/cm2(g), keeping the tube end plugged/crimped.

There shall be no physical damage to the fitting, and no leakage observed during
the seismic test.

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60614/PC-E-274 MAY, 2009

The test setup (.i.e. mounting of assembly on vibration table) and detailed test
procedure shall be proposed by the manufacturer and subject to approval of the
purchaser.

There shall be no physical damage to the fitting, and no leakage observed during
the seismic test.
All the tests will be witnessed by the purchasers authorized representative. The
bulk production shall be started only after approval of the prototype fittings by the
purchaser.

6.3.3 Acceptance Tests :

Following tests shall be carried out on each lot of the fittings.

6.3.3.1 Tests on Raw Material

Raw material for body, nut and ferrules shall be tested for physical properties
(i.e. tensile strength, percentage elongation, hardness etc.), chemical analysis,
IGC and ultrasonic tests as per the relevant ASTM standards such as ASTM-A-
276, ASTM-A- 262 and NPCIL specification PP-P-1214. Physical test, chemical
analysis and IGC shall be carried out on the sample from each heat, whereas
ultrasonic test shall be carried out on 100% quantity.

6.3.3.2 Dimensional Checks

The following dimensional checks shall be carried out on 1% quantity of each
size and type of fittings (minimum 5 numbers) randomly selected by the
purchaser from each lot.

a) Complete checks of threads with the appropriate gauges/measuring
instruments..

b) Micrometer check on tool relief diameter.

c) Complete check of various dimensions of all components of fittings .

d) Visual check under magnification of ferrule surfaces, body seats and
threads.

e) Inspection of fittings for any forging imperfections (wherever applicable).

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6.3.3.3 Hardness Test

One body, one nut, one front ferrule and one back ferrule of each size which have
passed the dimensional checks shall be tested to check the hardness to confirm the
requirement as per Section 5.8. These fittings shall not be taken for any other
tests.
6.3.3.4 Pull Out Test

The test is needed to establish that in tube fitting assembly the tension load
required to pull out the tubing out of the fitting, is much more than the force
exerted by rated hydrostatic test pressure. Three fittings of each size from each
lot shall be subjected to pull out test.

The test assembly shall be placed in a tension testing machine. The tension load
on the tube shall be increased at a rate not more than 55 kg/minute. The tension
load required to pull out the tube from tube fitting assembly shall be recorded.
The tension load shall be at least 4 times the force exerted by rated hydrostatic
test pressure. The remaining tests (i.e. tests mentioned in sections 6.3.3.5 thru
6.3.3.12) shall be continued only after successful completion of pull out test and
shall be performed on fresh samples. The failure of pull out test abandons all
further tests and will be a cause for rejection of lot.

6.3.3.5 Hydrostatic Test :

1% quantity from lot of each size of fittings, randomly selected from the fittings
checked for the dimensions and hardness shall be selected for hydrostatic test.
The fittings and their component parts when assembled with SS tubing as per PP-
M-107, shall be subjected to internal hydrostatic test pressure of 300 kg/cm
2
(g).
The pressure shall be applied gradually at the rate of 1.5 to 3.5 kg/cm
2
(g) per
second and maintained at the test pressure for not less than 10 minutes. No
deformation or visual leakage shall be seen in any of the fittings. The tested fitting
samples shall be dried thoroughly before proceeding for further tests

6.3.3.6 Air Leak Test :

All the fittings which have undergone hydrostatic test shall be subjected to Air
Leak test. The fittings and their component parts when assembled with SS tubing
as per PP-M-107 shall be capable of withstanding an internal air pressure of 7
kg/cm
2
(g). The pressure shall be maintained for not less than 10 minutes and the
appearance of bubbles from any fitting when immersed in water, shall cause for
rejection.

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6.3.3.7 Re-assembly Test :

Two fittings of each size from the fittings undergone hydrostatic and air leak tests
shall be subjected to 25 assemblies and re-assemblies with SS-304 L tube as per
PP-M-107.

After every fifth re-assembly, the fittings shall pass hydrostatic test as per Section
6.3.3.5. and air leak test as per Section 6.3.3.6.

6.3.3.8Temperature Cycling :

At least one fitting of each size which has undergone re-assembly test shall be
subjected to three temperature cycles, each of approximately 4 hours duration. In
each cycle, time taken to reach the highest temperature (325
o
C) from the lowest
(27
o
C) shall not be less than one hour and not more than 1 hours. Then the
fittings shall be kept at the highest temperature for one hour. The temperature
shall then be brought down to the lowest value in 1 to 1 hours. At the end of
the test, the fitting shall pass the air leak test as specified in Section 6.3.3.6.

6.3.3.9 Pressure Cycling

All the fittings which have undergone temperature cycling shall be subjected to
pressure cycling test comprising of pressurizing to 200 kg/cm
2
(g) and suddenly
depressurizing to a pressure of 1 kg/cm
2
(g) or less, at a rate of 30 to 100
cycles/minute for minimum 10
5
cycles. At the end of this test the fitting shall be
subjected to and shall pass the air leak test as specified in Section 6.3.3.6.

6.3.3.10Vibration (Non-Seismic) Test :

The assembled fittings shall be capable of withstanding non-seismic vibration
without any leak or fatigue failure. All the fittings which have undergone
pressure cycling shall be subjected to non-seismic vibration test.

The fittings shall be assembled so as to give an unsupported tubing length of 0.5
metre and subjected to vibrations for at least 5 x 10
5
cycles in each of two
mutually perpendicular directions. The frequency shall be 25 to 50 cycles per
second and the amplitude of oscillation shall be such so as to stress the tube to
25% of its tensile yield.

The fitting shall be rigidly fixed on a static test platform and the free end of the
tubing shall be subjected to vibrations. During vibration test the tube fitting

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assembly shall be subjected to an internal pressure of 200 kg/cm
2
(g). The tube
fitting assembly may be pressurized from tube fitting end, keeping the tube end
plugged/crimped. The amplitude of oscillation shall be calculated based on
actual value of unsupported tube length in the test set up. At the end of this test
the fitting assemblies shall pass the air leak test as specified in Section 6.3.3.6.

The overall test procedure/test set up for this test shall be proposed by the
supplier/vendor and shall be subject to Purchasers approval.

6.3.3.11 Helium Leak Test

At least one fitting of each size, randomly selected from the lot of the
dimensionally checked fittings (as per section 6.3.3.2) and all the fittings which
have undergone all above tests upto non-seismic vibration test, shall be subjected
to helium leak test. The helium test pressure shall be 1 kg/cm
2
(g). Overall leak
rate shall not exceed 10
-6
standard cc/sec.

6.3.3.12 Final Pull Out Test

All the fittings which have undergone the tests mentioned in Section 6.3.3.5 thru
6.3.3.11 shall be subjected to final pull out test as specified in section 6.3.3.4.
6.3.3.13 Inspection And Test Failure

In the event of failure of sample fittings from a lot to meet the inspection and test
requirements specified herein, the entire lot will be rejected and the contractor
shall notify the Purchaser or his authorized representative.

7.0 DOCUMENTATION :
Schedules of submission of various documents by the Contractor are given in
following sections. All the documents shall be signed by the authorized
representative of the Contractor.

7.1 Documents to be furnished by the bidder alongwith the offer

All the documents listed below shall be furnished in triplicate along with the
offer.
a) Detailed technical literature on the offered fittings, indicating various
types, sizes, dimensions, material of construction, service conditions, tests
carried out, installation procedures, applicable standards etc.

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b) List of in-house manufacturing facilities.

c) List of in-house inspection and test facilities.

d) Standard QA plan followed by the bidder in the manufacture of tube
fittings, indicating incoming/in-process and final inspection & testing.

e) Quality Manual of the company.

f) Reference list of the customers to whom similar fittings have been
supplied and operating satisfactorily, indicating quantities supplied,
purchase order reference, order values, scheduled delivery dates and actual
dates of supply.

g) Lists of suppliers/sub-vendors of various materials and components used
in manufacturing of the SS tube fittings.

h) Point wise confirmation on each clause of this specification explaining
how the requirements are being met.

i) Copies of the test reports if the offered fittings have earlier undergone
various tests mentioned in this specification.

7.2 Documents required to be furnished immediately after placement of
Purchase Order

Immediately after placement of purchase order, three copies of following
documents shall be submitted for the Purchasers review and approval. The
Contractor shall commence manufacturing/testing of the equipment only after
specific approval of the relevant documents by the Purchaser.

a) General arrangement drawing of each type of fittings indicating overall
dimension, component dimensions and tolerances, material of construction
of each component hardness values, finish etc.

b) Detailed quality assurance plan indicating incoming, in-process and final
inspection and tests.

c) Detailed procedures for all the tests to be carried out on the equipment.

7.3 Documents required to be furnished alongwith the supply

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a) Five copies of all as-built drawings, bill of material as covered in section
7.2 (a) along with their reproducibles.
b) Six copies of operation and maintenance manual giving functional
description, descriptive and illustrative literatures of all the components
sub assemblies, installation procedure etc. Six soft copies of the same shall
also be supplied in the form of CD/DVD .

c) Six sets of history dockets containing all material certificates/reports and
test reports. Six soft copies of the same shall also be supplied in the form
of CD/DVD.

In addition to the above, the manufacturer shall supply in triplicate,
certificate of compliance stating that the material supplied is in accordance
with all the provisions of this specification.

8.0 IDENTIFICATION : Each fitting shall be individually packed in a cellophane
bag along with an identification slip bearing the part number of the fitting.

Fittings of each type and size shall be packed in separate packages. All the
packages shall be clearly and legibly marked in suitable permanent manner with
the following information :
a) Purchase Order Number of the Purchaser

b) Item number of the Purchase Order
c) Details of the fittings and quantity of each type of fittings in the packages

9.0 PACKING & SHIPPING :
The Contractor shall make adequate provisions to protect the fittings supplied to
this Specification to ensure that, on arrival at the generating station or elsewhere
as may be advised by the Purchaser and after storage as may occur, they will not
have suffered corrosion, damage, or deterioration of any sort. The threads of all
the fittings shall be protected with suitable plastic caps/plugs. The packing shall
be suitable for tropical climate.

In no case will the supplier ship the material without obtaining written permission
or shipping release from the buyer or his authorized representative. Material shall
be shipped only after completion of all inspection and test formalities.

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TABLE - I
DIMENSIONAL TOLERANCES OF TUBE FITTINGS
DIMENSIONAL TOLERANCES OF TUBE FITTINGS IN METRIC SIZES

Size of
Fittings (Tube
O.D.)
Nut
ID
mm
Front ferrule
ID
mm
Back ferrule
ID
mm
Body
ID
mm
3 mm. 3.20
3.13
3.20
3.13
3.20
3.13
3.20
3.13
6 mm. 6.20
6.13
6.20
6.13
6.20
6.13
6.20
6.13
10 mm. 10.20
10.13
10.20
10.13
10.20
10.13
10.20
10.13
12 mm. 12.20
12.13
12.20
12.13
12.20
12.13
12.20
12.13
16 mm 16.22
16.15
16.22
16.15
16.22
16.15
16.22
16.15
18 mm. 18.22
18.15
18.22
18.15
18.22
18.15
18.22
18.15
20 mm. 20.22
20.15
20.22
20.15
20.22
20.15
20.22
20.15
25 mm 25.22
25.15
25.22
25.15
25.22
25.15
25.22
25.15

DIMENSIONAL TOLERANCES OF TUBE FITTINGS IN INCH SIZES
Size of
Fittings (Tube
O.D.)
Nut
ID
mm
Front ferrule
ID
mm
Back ferrule
ID
mm
Body
ID
mm
1/8 (0.125) 0.133
0.130
0.133
0.130
0.133
0.130
0.133
0.130
1/4 (0.250) 0.258
0.255
0.258
0.255
0.258
0.255
0.258
0.255
1/2 (0.500) 0.508
0.505
0.508
0.505
0.508
0.505
0.508
0.505
5/8 (0.625) 0.633
0.630
0.633
0.630
0.633
0.630
0.633
0.630
3/4 (0.750) 0.758
0.755
0.758
0.755
0.758
0.755
0.758
0.755
1"(1.000) 1.010
1.007
1.010
1.007
1.010
1.007
1.010
1.007

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TABLE- II
DIMENSIONAL TOLERANCES OF SS TUBES

DIMENSIONAL TOLERANCES OF SS TUBES (METRIC SIZES)

Outside dia (mm) Wall thickness (min.)
(mm)
Tolerances on O.D. (mm)
3 1.0 -0.00 + 0.10
6 1.2 -0.00 + 0.10
10 1.2 -0.00 + 0.10
12 1.5 -0.00 + 0.10
16 1.8 -0.00 + 0.12
18 2.1 -0.00 + 0.12
20 2.5 -0.00 + 0.12
25 3.0 -0.00 + 0.12

DIMENSIONAL TOLERANCES OF SS TUBES (INCH SIZES)

Outside dia inch Wall thickness (min.) inch Tolerances on O.D. inch
1/8 0.018 -0.000 + 0.002
1/4 0.049 -0.000 + 0.004
3/8 0.035 -0.000 + 0.004
3/8 0.049 -0.000 + 0.004
1/2 0.065 -0.000 + 0.005
5/8 0.065 -0.000 + 0.005
3/4 0.095 -0.000 + 0.005
7/8 0.095 -0.000 + 0.005
1 0.109 -0.000 + 0.005

ON

Page 17 of 20
Rev. 0

60614/PC-E-274 MAY, 2009

ANNEXURE-I
11. SAMPLE QUALITY ASSURANCE PLAN FOR STAINLESS STEEL COMPRESSION TYPE (FLARELESS) TUBE
FITTINGS

SL.
NO.

1
COMPONENT/
OPERATION

2
CHARACT-
ERISTIC

3
TYPE
OF
CHECK
4
CLASSIF-
ICATION

5
QUANTUM
OF CHECK

6
REFERENCE
DOCUMENT

7
ACCEPTANCE
NORMS

8
FORMAT
OF
RECORD
9
AGENCY

(P)(W)(V)
10
REMARK

11

1.0
RAW MATERIAL

Material for
body, nut &
ferrules

Chemical
Composition

Chemical
Analysis

MA

Sample from
each heat

Applicable
standards

Applicable
Standards

Test Report

3 2 1

To be done
in NPCIL
Approved
Lab

Non destructive
examination

Ultrasonic
Test

MA

100%

As per
PP-P-1214

ASTM
Standard

Test Report

3 2 1

To be done
in NPCIL
Approved
Lab

Physical
properties

Tensile
Strength
Hardness &
IGC Test

MA

Sample from
each heat

Applicable
standards

Applicable
Standards

Test Report

3 2 1

To be done
in NPCIL
Approved
Lab

ON

Page 18 of 20
Rev. 0

60614/PC-E-274 MAY, 2009

SL.
NO.

1
COMPONENT/
OPERATION

2
CHARACT-
ERISTIC

3
TYPE
OF
CHECK
4
CLASSIF-
ICATION

5
QUANTUM
OF CHECK

6
REFERENCE
DOCUMENT

7
ACCEPTANCE
NORMS

8
FORMAT
OF
RECORD
9
AGENCY

(P)(W)(V)
10
REMARK

11

2.0
IN PROCESS/ROUTINE TEST
2.1 Checks on
Components
Threads Check Gauging MA 100% Manufact-urers
drawings
Manufact-urers
drawings
IQC Records 2 2 1
Dimensional
check on body,
nut, front
ferrule and back
ferrule
Measur-
ement
MA 100% Manufact-urers
drawings
Manufact-urers
drawings
IQC Records 2 2 1
2.2

Assembled
Fittings
Finish Visual MA 100% Manufact-urers
drawings
As per NPCIL
approved
drawing
Test Report 2 2 1
Overall
Dimensions
Measur-
ement
MA 100% Manufact-urers
drawings
As per NPCIL
approved
drawing
Test Report 2 2 1

3.0

ACCEPTANCE TEST
3.1 Body Dimensional
check
Measure-
ment
MA 2% of the lot NPCIL
approved
drawings
NPCIL approved
drawings
Test Report

2 1 1
Hardness Hardness
Test
MA 1 sample from
each lot
As per 4.8 of
PP-E-577
As per 4.8 of PP-
E-577 and plant
standard
Test Report 2 1 1
3.2 Nut Dimensional
check
Measure-
ment
approved
drawings
NPCIL approved
drawings
IQC Records 2 1 1

ON

Page 19 of 20
Rev. 0

60614/PC-E-274 MAY, 2009

SL.
NO.

1
COMPONENT/
OPERATION

2
CHARACT-
ERISTIC

3
TYPE
OF
CHECK
4
CLASSIF-
ICATION

5
QUANTUM
OF CHECK

6
REFERENCE
DOCUMENT

7
ACCEPTANCE
NORMS

8
FORMAT
OF
RECORD
9
AGENCY

(P)(W)(V)
10
REMARK

11
Hardness Hardness
Test
MA 1 sample per
size from each
lot
As per 4.8 of
PP-E-577
As per 4.8 of PP-
E-577 and plant
standard
Test Report 2 1 1
3.3 Front Ferrule Dimensional
check
Measure-
ment
approved
drawings
NPCIL approved
drawings
IQC Records 2 1 1
Hardness Hardness
Test
MA 1 sample per
size from each
lot
As per 4.8 of
PP-E-577
As per 4.8 of PP-
E-577 and plant
standard
Test Report 2 1 1
3.4 Back Ferrule Dimensional
check
Measure-
ment
approved
drawings
NPCIL approved
drawings
IQC Records 2 1 1
Micro Hardness Micro
Hardness
Test
MA 3 samples per
size from each
lot
As per 4.8 of
PP-E-577
As per 4.8 of PP-
E-577 and plant
standard
Test Report 2 1 1
3.5 Assembled
Fitting
Dimensional
check
Measure-
ment
MA 2% from each
lot
NPCIL
approved
drawings
NPCIL approved
drawings
IQC Records 2 1 1
3.5.1 Assembled
Fitting
Tension pull out
test
Perform-
ance
MA 1 fitting from
each size
As per 6.3.3.3
& 6.3.3.12 of
PP-E-577
NPCIL
Approved Test
Procedure
Test Report 2 1 1
3.5.2 Assembled
Fitting
Material
integrity and
strength
Hydro-static
Test
MA 1% of fitting As per NPCIL
approved test
procedure
As per NPCIL
approved test
procedure
Test Report 2 1 1
3.5.3 Assembled
Fitting
Leak tightness Air Leak
Test
MA 1% of fitting As per NPCIL
approved test
procedure
As per NPCIL
approved test
procedure
Test Report 2 1 1

ON

Page 20 of 20
Rev. 0

60614/PC-E-274 MAY, 2009

SL.
NO.

1
COMPONENT/
OPERATION

2
CHARACT-
ERISTIC

3
TYPE
OF
CHECK
4
CLASSIF-
ICATION

5
QUANTUM
OF CHECK

6
REFERENCE
DOCUMENT

7
ACCEPTANCE
NORMS

8
FORMAT
OF
RECORD
9
AGENCY

(P)(W)(V)
10
REMARK

11
3.5.4 Assembled
Fitting
Reusability Re-assembly
Test
2 fittings from
each size
As per NPCIL
approved test
procedure
As per NPCIL
approved test
procedure
Test Report 2 1 1
3.5.5 Assembled
Fitting
Performance Temper-
ature cycling
test
MA 1 fitting from
each size
As per NPCIL
approved
procedure
As per NPCIL
approved
procedure
Test Report 2 1 1
3.5.6 Assembled
Fitting
Performance Pressure
Cycling Test
MA 1 fitting from
each size
As per NPCIL
approved
procedure
As per NPCIL
approved
procedure
Test Report 2 1 1
3.5.7 Fitting Assembly Performance Non-
Seismic
Vibration
MA 1 fitting from
each size
As per NPCIL
approved
procedure
As per NPCIL
approved
procedure
Test Report 2 1 1
3.5.8 Fitting Assembly Performance Seismic
Vibration
Test
MA 1 fitting from
each size
As per NPCIL
approved
procedure
As per NPCIL
approved
procedure
Test Report 2 1 1 To be
carried out
only on
prototype
fittings
3.5.9 Fitting Assembly Leak Tightness Helium
Leak Test
MA Quantity as per
Clause
6.3.3.11
PP-E-577
As per NPCIL
approved
procedure
As per NPCIL
approved
procedure
Test Report 2 1 1
3.6 Fittings Packing
& Dispatch

Final Assembly Visual MA 100% As per NPCIL
approved
specification
Approved
procedure
-- 2 1 1
LEGEND :
P = Performed by. V=Verified by 1. NPCIL
W = Witnessed by. MA=Major 2. Manufacturer 3. Third Party

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