The Information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED. It must not be used directly or indirectly in any way detrimental to the Interest of the company. COPYRIGHT AND CONFIDENTIAL
Probable / Suggested Suppliers and Grades:
Refer plant vendors list
User Plants and Replaced Plant Specifications / References:
1) HEP, BHOPAL : PS113108
2) HPEP, HYDERABAD : CSN 422425, 422430, DIN 1691, GG25, IS 210, Gr 25 3) HEEP, HARDWAR : 0500.301, Gr: 25 4) HPBP, TIRICHY : IS:210, Gr: 25
Revisions: APPROVED: Refer 43.3 of MOM of MRC-FCF+HTM INTERPLANT MATERIAL RATIONALISATION COMMITTEE – MRC(FCF+HTM) Rev No.07 Amd No. Reaffirmed Prepared Issued Dt. of 1 st Issue HEP, Bhopal Corp.R&D December 1977 Dt:22-04-2021 Dt: Year: This page intentionally left blank AA19703
CORPORATE PURCHASING SPECIFICATION Rev No. 07
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GREY IRON CASTINGS - Gr: FG 260
1 GENERAL This specification governs the quality requirements of Grey Iron Castings having a tensile strength of 260 N/mm 2
2 APPLICATION Suitable for general engineering purposes.
3 CONDITION OF DELIVERY The Information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED. It must not be used directly or indirectly in any way detrimental to the Interest of the company.
As cast or cast and stress relieved or rough machined or rough machined and stress relieved as specified in BHEL order/drawing.
Castings shall not be painted.
4 COMPLIANCE WITH NATIONAL STANDARD
Castings shall comply with the following national standards and also meet the requirements of this specification. COPYRIGHT AND CONFIDENTIAL
IS: 210-2009, Gr: FG 260 : Grey Iron Castings
5 DIMENSION AND TOLERANCES
Castings shall be true to the pattern / drawing.
Holes for machining up to and including 50mm in diameter are to be cast solid, unless otherwise stated in BHEL order / drawing.
Unless otherwise specified in BHEL order/ drawing, untoleranced dimensions for the casings shall be as per tolerance class 5 of BHEL standard AA0230402.
6 MANUFACTURE The castings shall be cast from the metal melted or refined in any suitable cupola or Electric / Induction furnace or as agreed between supplier and BHEL.
All castings above five tonnes shall be mould cooled. Under mould cooling process, the mould should not be disturbed until the hottest portion of the casting cools down to 300°C.
7 HEAT TREATMENT Castings shall be stress relieved by heating in a furnace to a temperature of 520 to 580°C (recommended), whenever specified.
Test pieces shall also be heat treated along with the castings they represent.
8 FINISH All castings shall be properly fettled and dressed and all surfaces shall be thoroughly cleaned. Whenever specified, the machined surfaces shall have the surface finish as indicated in the drawing.
Revisions: APPROVED: Refer 43.3 of MOM of MRC-FCF+HTM INTERPLANT MATERIAL RATIONALISATION COMMITTEE – MRC(FCF+HTM) Rev No.07 Amd No. Reaffirmed Prepared Issued Dt. of 1 st Issue HEP, Bhopal Corp.R&D December 1977 Dt:22-04-2021 Dt: Year: AA19703 Rev No. 07 CORPORATE PURCHASING SPECIFICATION PAGE 2 of 5
9 FREEDOM FROM DEFECTS
Castings shall sound, clean, free from defects such as porosity, blow holes, sand inclusions, shrinkage's, cavities, hard spots, cold shuts, cracks, etc. which may adversely affect machining and utility of castings.
No welding or repairs shall be carried out without permission of BHEL. Welding referred to here includes fusion welding in accordance with common foundry practice. The method of repair by welding (see IS 5139) and subsequent stress-relieving shall be as agreed to between the purchaser and the manufacturer.
10 CHEMICAL COMPOSITION The composition of iron is left to the discretion of the manufacturer, but maximum limit for Phosphorous and / or Sulphur may be specified by the purchaser, if desired. In case of special castings, the detail chemical composition shall be agreed to between the purchaser and the manufacturer.
11 TEST SAMPLES Manufacturers shall carryout mechanical testing as per following sampling plan.
11.1 Provision of Test Bars
All the test bars shall be cast separately in sand moulds and the number of test bars required shall be as specified in clause 11.2 below. They shall be cast at the same time and from the same melt as the castings, they represent. The test bar material shall be identifiable with that of the castings represented.
When castings are subjected to heat treatment and the test bars shall be heat treated together with the castings they represent.
The test bars shall be cast in dried, baked or chemically bonded moulds made mainly of aggregate of siliceous sand with appropriate binders. The average grain size of the sand shall be approximate to that of the sand in which the castings are poured. Moulds for the test bars shall be approximately at room temperature when poured. More than one test bar may be cast in a single mould, but each bar may be cast in a single mould, but each bar in the mould shall be surrounded by thickness of sand which is not less than the diameter of the bar.
11.2 Frequency of Testing
The number of tests required for each melt or batch of castings shall be as laid in Table 1 below.
Table 1 – Number of Tests
Group Mass of individual Castings Test Requirements Test Samples
*1 Up to 12.5 kg One test for every 500kg of castings or part thereof 3 *2 over 12.5 kg and up to 50 kg One test for every 1 tonne of castings or part thereof 3 *3 over 50 kg and up to 500 kg One test for every 2 tonnes of castings or part thereof 3 *4 over 500 kg and up to 1 tonne One test for every 3 tonnes of castings or part thereof 3 5 over 1 tonne One test for every 4 tonnes of castings or part thereof or 3 One test for every casting weighing 4 tonnes or more
* In group 1, 2, 3 & 4 all castings represented by one test shall be poured from the same ladle or same heat as the bars provided for the test 11.3 Size of Test Bars A test bar from which the tensile test piece is machined shall be cast as a uniform cylindrical bar of 30mm diameter. The tolerance on the diameter shall be +2mm, -0 mm. The minimum length of the test bar shall be 230mm. AA19703
CORPORATE PURCHASING SPECIFICATION Rev No. 07
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11.4 Dimensions of Test Pieces
Test pieces shall conform to the dimensions as per IS:210. Note: Test bars as specified above with proper identification and representative of the castings shall be supplied along with the consignment.
12 MECHANICAL PROPERTIES 12.1 Tensile The test pieces prepared in accordance with clause 11 shall show a tensile strength of 260 N/mm 2 , minimum, when tested in accordance with IS:1608.
12.2 Hardness (Brinell)
Hardness shall be measured on actual casting at three different places. The castings shall have a Brinell hardness in the range of 180 to 230 HB, when tested in accordance with IS 1500.
13 OPTIONAL TESTS If specified in the drawing/order, the following tests shall be conducted.
13.1 Non-destructive test
Magnetic Particle Inspection as per BHEL standard AA0850133 and norms of acceptance as per AA0850134 at level 2.
13.2 Hydraulic Hydraulic test shall be conducted by the manufacturer. In case hydraulic testing as prescribed on the BHEL order/drawing is not carried out at the manufacturer's works, the same shall be carried out by BHEL after necessary machining. However, the manufacturer shall guarantee against any leakage when tested at BHEL's end.
Test pressure and duration of test shall be as specified in BHEL order/drawing.
14 RETEST Retest shall be done as per IS:210.
15 REPAIR OF CASTINGS Repair of castings shall not be carried out by the manufacturer without the prior permission of BHEL.
16 SCOPE OF THIRD PARTY INSPECTION
Wherever, separate quality plan is not attached, the scope of third party inspection shall be as follows:
1) Review of supplier’s declared chemical composition.
2) Selection of test samples for mechanical tests and witness of mechanical tests. 3) Witness of Non-destructive tests as applicable. 4) Review of HT charts. 5) Dimensional inspection.
17 TEST CERTIFICATES Three copies of test certificates shall be supplied unless otherwise stated on order, preferably in the test certificate format annexed to this specification (Annexure -1).
In addition, the supplier shall ensure to enclose one copy of the test certificate along with their dispatch documents to facilitate quick clearance of the material. AA19703 Rev No. 07 CORPORATE PURCHASING SPECIFICATION PAGE 4 of 5
The following details shall be furnished in the test certificate:
1) Dimensional inspection 2) Detail of heat treatment 3) Hardness value 4) NDT 5) Optional tests called for in the drawing/order.
18 PACKING AND MARKING
Castings shall be suitably packed to prevent corrosion and damage during transit. Machined surfaces shall be properly protected with anticorrosive compounds. Each package or casting (when supplied separately) shall be legibly marked with the following information.
– AA19703: GREY IRON CASTINGS - Gr: FG 260
– BHEL Order No. – Consignment/Identification No. – Melt No. – Weight – Supplier's Name
19 REFERRED STANDARDS (Latest Publications Including Amendments):
Element C Si Mn S P As per Min. Specn. Max. Actual Values 17. HEAT TREATMENT (To be accompanied by Recorder Chart, Whenever Called for)
Condition Temp. ºC Soaking Time, Hrs. Cooling Medium
14. MECHANICAL PROPERTIES
Hardness T.S. Y.S. 0.5/0.2% % Elongation % R.A. Impact value BHN (Min.3 Bend N/mm2 Proof N/mm2 5.65vSo GL Min. Joules values)
As per Min. Specn. Max. Actual Values 15. SURFACE FINISH (When called for in the order / drg.) 16. DIMENSIONAL INSPECTION
17. NON-DESTRUCTIVE TESTS
Nature of Test Acceptance Instrument used Range Results Any other detail level Ultrasonic Radiographic Dye penetrant/ Magnetic Particle 18. OTHER TESTS IF ANY (Microscopic, Hydraulic, Etc)
19. IDENTIFICATION OF CASTINGS AS PER CPS
We hereby certify that the items mentioned above have been tested and inspected in our presence and are found to be in accordance with drawings, specifications and purchase order.
Signature & Seal of the inspecting Officer Signature and Seal of the Chief of Quality Control (Purchase Representative) Chief Metallurgist of Supplier. Date : INSTRUCTIONS a) If steel is produced by LD or Oxygen process, Nitrogen content should be furnished and shall not exceed 0.009%. b) Test certificates are to be furnished as per purchase order and specification, in A4 size transparent paper. c) All the entries including signature should be in block colour ink. d) If testing is done by outside agencies, the original TCs shall be furnished. e) The actual Test Certificate may run into more than one A4 size paper, if needed, to facilitate filling up of details.
