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    AE-S-3527 Rev. 2: REV Prepared by Approved BY Date Remarks

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    This document specifies requirements for seamless cold drawn low carbon steel tubes and U-tubes, including: - Material specifications for tubes up to 38.1mm OD and 3.4mm thickness made of low carbon steel. U-tubes must be stress relieved after bending. - Chemical composition limits for carbon, manganese, phosphorus, and sulfur. - Dimensional tolerances for straight tubes and U-tube dimensions including thickness, diameter, length, bend radius, and leg lengths. - Requirements for fabrication, heat treatment including stress relieving, non-destructive testing, mechanical tests, and scope of inspection.

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    AE-S-3527 Rev. 2: REV Prepared by Approved BY Date Remarks

    Uploaded by

    Quality
    118 views6 pages
    This document specifies requirements for seamless cold drawn low carbon steel tubes and U-tubes, including: - Material specifications for tubes up to 38.1mm OD and 3.4mm thickness made of low carbon steel. U-tubes must be stress relieved after bending. - Chemical composition limits for carbon, manganese, phosphorus, and sulfur. - Dimensional tolerances for straight tubes and U-tube dimensions including thickness, diameter, length, bend radius, and leg lengths. - Requirements for fabrication, heat treatment including stress relieving, non-destructive testing, mechanical tests, and scope of inspection.

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    This document specifies requirements for seamless cold drawn low carbon steel tubes and U-tubes, including: - Material specifications for tubes up to 38.1mm OD and 3.4mm thickness made of low carbon steel. U-tubes must be stress relieved after bending. - Chemical composition limits for carbon, manganese, phosphorus, and sulfur. - Dimensional tolerances for straight tubes and U-tube dimensions including thickness, diameter, length, bend radius, and leg lengths. - Requirements for fabrication, heat treatment including stress relieving, non-destructive testing, mechanical tests, and scope of inspection.

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    © All Rights Reserved
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    Download as doc, pdf, or txt
    118 views6 pages

    AE-S-3527 Rev. 2: REV Prepared by Approved BY Date Remarks

    Uploaded by

    Quality
    This document specifies requirements for seamless cold drawn low carbon steel tubes and U-tubes, including: - Material specifications for tubes up to 38.1mm OD and 3.4mm thickness made of low carbon steel. U-tubes must be stress relieved after bending. - Chemical composition limits for carbon, manganese, phosphorus, and sulfur. - Dimensional tolerances for straight tubes and U-tube dimensions including thickness, diameter, length, bend radius, and leg lengths. - Requirements for fabrication, heat treatment including stress relieving, non-destructive testing, mechanical tests, and scope of inspection.

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    of 6

    SPECIFICATION FOR SEAMLESS COLD DRAWN LOW CARBON

    STEEL TUBES INCLUDING U - TUBES

    1.0 SCOPE

    This specification covers the manufacturing, fabrication, heat treatment and testing
    requirements of seamless cold drawn low carbon steel straight tubes and U – tubes
    manufactured by bending of straight tubes.

    Applicable standards

    ASTM A - 179 : Specification for seamless cold drawn low carbon


    steel heat exchanger and condenser tubes.
    ASTM A - 450 : Specification for general requirements for carbon,
    ferritic alloy and austenitic alloy steel tubes.

    2.0 MATERIAL SPECIFICATION

    Item : Seamless cold drawn low carbon steel straight and


    U - tubes. ➁

    Size : Upto 25.4 mm ( 1” ) OD and 3.0 mm thickness.


    Above 25.4 mm up to 38.1mm (1-1/2") incl. OD and
    3.4 mm thickness . ➁

    Condition : All tubes shall be heat treated as per clause 6.0 of A-


    179. Additionally U-tubes shall be stress–relieved
    after bending in the bent portion and a minimum
    300 mm from tangent lines. 

    2 TKSG PJMR 04.05.2010 Revision as marked. ➁


    1 VMP PBP 25.01.99 Revision as marked , Change in format.
    0 DPP GMS 30.06.93 Original
    REV PREPARED BY APPROVED DATE REMARKS
    BY

    BHARAT PETROLEUM CORPORATION COMPANY STANDARD PAGE


    LIMITED, MAHUL REFINERY. SPECIFICATION NO.
    (ADVISORY ENGINEERING) AE-S-3527 Rev. 2 1 OF 6
    35601
    Service : Reboiler , heat exchanger, sulphur condenser etc.
    (excluding sea water service). ➁

    Manufacture : Tubes shall be made seamless by cold drawn process


    followed by stress relieving. U bending of tubes
    shall be carried out as per BPCL approved drawing
    followed by stress relieving. ➁

    3.0 CHEMICAL COMPOSITION

    Carbon : 0.06 – 0.18 %


    Manganese : 0.27 – 0.63
    Phosphorous : 0.035 (max)
    Sulphur : 0.035 (max)

    4.0 DIMENSIONAL TOLERANCES 

    4.1 Dimensional Tolerance for straight tubes and straight portion of U-tubes

    Outside Diameter : Each length of tube shall have following tolerance on outside
    diameter throughout the length.

    Upto 25.4 mm (incl) : +/- 0.1 mm.


    Above 25.4 mm up to 38.1 (incl) : +/- 0.15 mm. ➁

    Wall Thickness : The allowable percentage variation shall be + 10 % and -0 %

    Length : Tolerance on length at either ends of tube shall be + 3.0 mm and - 0 mm

    4.2 Dimensional Tolerance for bent portion of U-tubes. 

    4.2.1 Minimum tube wall thickness at the U-bend shall be calculated as follows;

    Tf = To / { 1 + ( D / 4R) } ➁

    Where Tf = min. tube wall thickness after bending , To = tube wall thickness before
    bending , R = mean radius of U-bend and D = Tube O.D.

    BHARAT PETROLEUM CORPORATION COMPANY STANDARD PAGE


    LIMITED, MAHUL REFINERY. SPECIFICATION NO.
    (ADVISORY ENGINEERING) AE-S-3527 Rev. 2 2 OF 6
    35601
    The calculated thickness Tf shall not be less than the required minimum tube wall
    thickness as specified in ASTM A-450.

    U-bends formed from tube materials that are relatively non-work-hardening and are of
    suitable temper, tube wall thinning shall not exceed 17% of the original tube wall
    thickness. ➁

    4.2.2 Flattening after bending shall not exceed 10% of the nominal tube OD. ➁

    4.2.3 The bent portion of U-tubes shall be substantially uniform in curvature and shall not
    exceed +/- 1.5 mm of the nominal centre line radius.

    4.2.4 The centre to centre distance between legs at the tangent line of U-bend portion shall
    have tolerance of +/- 1.0 mm .

    4.2.5 The length of tube leg as measured from the point of tangency of the bend to the
    end of the tube leg shall be within +3 / -0 mm. The difference in the lengths of the
    tube leg on either side shall not exceed 3 mm.

    5.0 FABRICATION OF U-BENDS

    i. Each length of straight tube shall be U-bend to required radius as per BPCL
    drawing.
    ii. Vendor shall manufacture templates or use jigs & fixtures of required radius to
    check individual tubes after U-bending.
    iii. Vendor shall fabricate mock-up tube sheet or use jigs & fixtures of required
    radius and check the assembly of U-tubes at least on one plane containing all
    radii. This check shall be carried out by vendor for each tube after completion of
    stress relieving.
    iv. Presence of kinks, wrinkles, flattening at bends and such other defects arising
    during fabrication shall be a cause for rejection.

    6.0 HEAT TREATMENT

    i. After completion of each draw / final cold draw, pass bending, each tube shall be
    stress relieved as follows :
    Uniform heating rate : 100 to 125 deg. C./.hour.
    Soaking temperature : 600 deg. C. to 650 deg. C.

    Soaking time : Minimum 15 minutes.


    BHARAT PETROLEUM CORPORATION COMPANY STANDARD PAGE
    LIMITED, MAHUL REFINERY. SPECIFICATION NO.
    (ADVISORY ENGINEERING) AE-S-3527 Rev. 2 3 OF 6
    35601
    Controlled cooling : Upto 300 deg. C. in furnace
    followed by cooling in still air.

    ii. Vendor shall offer the relevant heat treatment chart for third party / BPCL
    inspection scrutiny.

    iii. After completion of heat treatment, all tubes shall be descaled and pickled
    externally and internally.

    7.0 TESTS ON FINISHED TUBES

    i. Dye Penetrant Test :

    DP Test shall be carried out on bend portion of each U-tube to detect presence
    of cracks etc. and shall be certified by the vendor.

    ii. Hydrotest :

    Hydrotest of each finished tube shall be carried out as per Clause 22 (Table 7)
    of ASTM A-450. Hydrotest report for all tubes shall be submitted by vendor.
    Any failure during hydrostatic testing shall require witnessing of hydrotest of all
    tubes.

    iii. Hardness Survey :

    The hardness of finished tubes shall not exceed 130 BHN (72 HRB) at any
    location.

    iv. Other Tests :

    Vendor shall arrange to carry out flattening test and flaring test as per A-450 on
    one straight tube or straight leg of U-tube randomly selected by third party /
    BPCL inspection and offer the results for verification. The tested tube shall be
    replaced with a new tube.

    8.0 SCOPE OF BPCL / THIRD PARTY INSPECTION

    The manufacturer shall offer inspection of tubes to BPCL / third party inspection.

    During final inspection, the following shall be witnessed and certified by BPCL / third
    party inspection on finished tubes (including U-tubes) : ②

    BHARAT PETROLEUM CORPORATION COMPANY STANDARD PAGE


    LIMITED, MAHUL REFINERY. SPECIFICATION NO.
    (ADVISORY ENGINEERING) AE-S-3527 Rev. 2 4 OF 6
    35601
    i. Spectro analysis test of minimum two tubes of the heat / lot no. being delivered.
    ii. Physical witnessing of tensile test, yield test and elongation test.
    iii. Witnessing flattening and flaring test of one no. randomly selected finished tube.
    iv. Visual inspection of all tubes.
    v. Dimensional OD / thickness / length measurement & recording of 10% randomly
    selected tubes.
    vi. Hardness checking within six inches length on both tube ends and recording of
    10% randomly selected finished tubes including U-tubes .
    vii. Randomly selected five tubes of each bend radii shall be checked against
    template and mock-up tube sheet assembly.
    viii. Carrying out DP test at bend portion of 10 % randomly selected finished U-
    tubes.
    ix. Witnessing hydrotest of 10 % randomly selected finished tubes which have
    been tested by the manufacturer.
    x. Randomly checking for all tube ends having been stamped with the relevant
    ASTM no., dimension, heat / lot no., PO no. and manufacturers name.
    xi. Review / stamping of the manufacturers test certificates.
    xii. Furnishing of third party inspection report and release note.

    Besides the above, inspection findings leading to presence of surface imperfection


    marks 0.3 mm and more in depth, scratch marks, kinks, wrinkles etc., ovality on
    OD, non-uniform bore, flattening at bends, adjacent tubes touching at bend portions
    for U-tubes, waviness occurred during improper stress relieving etc. shall be a cause
    for rejection of the lot.

    9.0 MANUFACTURER’S TEST CERTIFICATE

    Manufacturer with each lot of tubes shall submit Test Certificate with certification of
    all tubes having been manufactured in accordance with the stipulated standard /
    specification and duly stamped by the third party inspection. ②

    The test certificate shall clearly furnish the following information : ➁

    i. Certificate number and date.


    ii. Product description / dimensions / relevant standard.
    iii. Heat / lot no.
    BHARAT PETROLEUM CORPORATION COMPANY STANDARD PAGE
    LIMITED, MAHUL REFINERY. SPECIFICATION NO.
    (ADVISORY ENGINEERING) AE-S-3527 Rev. 2 5 OF 6
    35601
    iv. Chemical / physical test result.
    v. Hardness test result.
    vi. Flattening test result.
    vii. Flaring test result.
    viii. DP test result on bend portion of each tube.
    ix. Checking of each U-tube against template.
    x. Checking of each U-tube against mock-up tube sheet assembly.
    xi. Heat treatment charts.
    xii. Descaling / pickling details.
    xiii. Hydro test report.

    10.0 PACKING ②

    i. Each finished tube end shall be stamped with PO no., relevant ASTM no., heat /
    lot no., dimension and manufacturers name. Each bundle shall contain only tubes
    of one radii and the bend radius mentioned on the packing legibly.
    ii. PVC end caps shall be provided at both ends of each tube.

    11.0 MATERIAL ACCEPTANCE

    Non of the tests mentioned in this specification or third party inspection shall be
    waived off at any point of time. No material shall be inspected by warehouse inspection
    without receipt of the original copy of manufacturers test certificate duly stamped by
    BPCL / third party inspection, original BPCL / third party inspection report along
    with inspection release note. On receipt of the material at BPCL warehouse, the
    relevant certificates shall be reviewed and the material be inspected / tested if required
    for confirming the acceptability of the material. ➁

    BHARAT PETROLEUM CORPORATION COMPANY STANDARD PAGE


    LIMITED, MAHUL REFINERY. SPECIFICATION NO.
    (ADVISORY ENGINEERING) AE-S-3527 Rev. 2 6 OF 6
    35601

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