REVISION CONTROL SHEET DOCUMENT TYPE : TECHNICAL SPECIFICATION NO. : PC-M-309 TITLE : REV. NO. & DATE DESCRIPTION OF REVISION PREPARED BY CHECKED BY REVIEWED BY APPROVED BY
PAGE NO : 1 of 16 1. SCOPE This specification establishes the technical requirements for Austenitic Stainless Steel Pipe Fittings. These requirements are supplementary to the technical requirements of the applicable material specifications. 2. CONTENTS The requirements of this specification are presented under the following headings: Section Scope 1.0 Contents 2.0 Specifications, Codes/Standards 3.0 Material and Technical Requirements 4.0 Examination Procedure 5.0 Acceptance Standards 6.0 Repair of Pipe Fittings 7.0 Quality Control (QC) and Quality Assurance (QA) 8.0 Cleaning 9.0 Certification and Identification 10.0 Shipment 11.0 Standard Quality Assurance Plan for seamless S.S. Pipe Fittings Standard Quality Assurance Plan for welded S.S. Pipe Fittings Appendix-A Appendix-B 3. SPECIFICATIONS,CODES/STANDARDS All specifications, codes/standards listed below shall govern the tendering conditions. The latest revision, as available on the date of tendering shall be applicable. The manufacturer shall indicate the date of issue of the standards he proposes to use at the bidding stage itself. In the event of conflict between the provisions of this specification and the documents listed below, this specification shall govern.
PAGE NO : 2 of 16 3.1 Specifications, Codes/standards ASME Section III, Div.1 Subsection NB, NC & ND Section II Part A Section V Section IX ANSI ANSI B 16.5 ANSI-B 16.9 ANSI-B 16.11 ANSI B 16.25 ANSI B 16.28 ASME SA-182/ SA-182 M ASME SA-403/ SA-403 M ASME SA-312/ SA-312 M ASME SA 358/ SA-358 M ASME SA 240 / SA-240 M ASME SA-577 / SA-577 M ASME SA-578 / SA-578 M ASME SA-388/ SA-388 M ASME SE-94 ASME SE-142 ASME SE-165 ASME SE-213 ASME A 262 ANSI B 1.20.1 ANSI B 16.36 ANSI B 46.1 - Boiler and Pressure Vessel Code. - For Class 1, Class 2 & Class 3 Components - Ferrous Material Specification - Non Destructive Examination - Welding and Brazing Qualification - American National Standard Institute - Steel Pipe Flanges and Flanged Fittings - Factory made Wrought Steel Butt Welding Fittings - Forged Steel Fittings Socket Welding and Threaded - Butt Welding Ends - Wrought Steel Butt Welding Short Radius Elbows & Returns - Specification for Forged or Rolled Alloy Steel Pipe Flanges, Flanged Fittings & Valves and Parts for High Temperature Service. - Specification for Wrought Austenitic Stainless Steel Fittings. - Specification for Seamless and Welded Austenitic Stainless Steel Pipes. - Specification for Electric Fusion Welded Austenitic Chromium Nickel Alloy Steel Pipe for High Temperature Service. - Specification for Heat Resisting Chromium and Chromium Nickel Stainless Steel Plate, Sheet and Strip for Pressure Vessel. - Specification for Ultrasonic Angle Beam Examination of Steel Plates - Specification for Straight Beam Ultrasonic Examination of Plain and Clad Steel Plates for Special Application - Specification for Ultrasonic Examination of Heavy Steel Forgings - Recommended Practice for Radiographic Testing - Standard Method for Controlling Quality of Radiographic Testing. - Standard Test Method for Liquid Penetrant Examination - Standard methods for ultrasonic inspection of metal pipe and tubing. - Standard Procedure for Detecting Susceptibility to Intergranular Attack in Austenitic Stainless Steel. - Pipe Threads General Purpose (Inch) - Orifice Flanges - Surface Texture
PAGE NO : 3 of 16 ASTM E 381 - Method of macro etch testing products, inspection and rating comprising steel bars, billets, blooms and forgings. MSS - Manufactures standardization society of the valve and fittings industry. MSS SP 25 - Standard Marking System for Valve, Fittings, Flanges and Unions MSS SP 97 - Integrally Reinforced Forged Branch Outlet Fittings. NPCIL Specification PP-E-1209 - Specification for Liquid Penetrant Examination of Metallic Surfaces PP-E-1212 - Specification for Radiographic Examination of Welds 4.0 MATERIAL & TECHNICAL REQUIREMENTS Technical/inspection requirements stated herein, are in addition to the requirements of basic material specification. Dimensions and tolerances shall meet the requirement of applicable specifications viz. ANSI B 16.9, ANSI B 16.11, ANSI B 16.28, ANSI B 16.5 etc. SR elbows intended for Class-1 application shall further meet the minimum thickness requirement of NB 3642.2 (i.e. minimum thickness in the crotch region shall be 20% greater than the minimum thickness required for pipe). Integral reinforcement for branch opening shall satisfy the requirement given in ASME NB-3643. Pipe fitting have been classified in three classes namely Class 1,2 and 3, generally intended to correspond to Class-1,2 and 3 of ASME Section III, Div.1. Austenitic stainless steel pipe fittings shall be offered to grades and standards tendered and to the applicable SA material specifications. Technical requirements for the pipe fittings have been grouped into : Requirements for pipe fittings of seamless construction and Requirements for pipe fittings of welded construction using filler metal. Fittings shall not be manufactured by machining only from bar stock. However, with prior agreement with Purchaser, small fittings (less than 50 mm NB diameter) whose configuration is nearly a hollow cylinder or uniaxial and nearly parallel to the metal flow lines of the stock, may be machined from Forged and ultrasonically examined bars only. Standard fittings shall also conform to the appropriate ANSI standards as given below: i) Butt welding fittings - ANSI-B-16.9 & ANSI B 16.28 ii) Socket welding and screwed fittings - ANSI-B-16.11
PAGE NO : 4 of 16 iii) Threads on screwed fittings - ANSI-B-1.20.1 iv) Flanges - ANSI-B-16.5 v) Orifice Flanges - ANSI-B-16.36 vi) Integrally Reinforced Forged Branch Outlet Fittings MSS-SP-97 Special Non-standard fittings and piping components, viz headers, branched outlet fittings, lateral tees, etc. not covered by an appropriate ANSI standard shall conform to special dimensional requirements specified by, or to be agreed with the purchaser. The manufacturer shall demonstrate and validate their design by analytical means, supported by tests such as Burst test, the adequacy of such components with respect to compliance with reinforcement, transitions requirements etc. laid down by applicable codes and also establish that the component is equivalent in strength to a pipe of same size and wall thickness. The manufacturing stages/processes and aforesaid test procedures shall be subjected to Purchasers approval. 4.1 Requirements for Pipe Fittings of Seamless Construction The requirements for pipe fittings made out of seamless construction have been summarized in Table-1. These requirements are over and above the basic material specification. In addition, examination of Class 1, Class 2 and Class 3 pipe fittings shall comply with Clause 2550 of ASME Section-III NB, NC & ND respectively. 4.2 Requirements for Pipe Fittings of Welded Construction with Filler Metal 4.2.1 The requirements for fittings made out of pipes welded with filler metal have been summarized in Table-2. These requirements are over and above the basic material specifications. In addition examination of Class 1, Class 2 & Class 3 pipe fittings shall comply with Clause 2560 of ASME Section III NB, NC & ND respectively. 4.2.2 Fittings offered to ASME-SA 403 M and made out of pipe to specification SA 312/SA 312 M & SA 358/SA 358 M shall also comply with the following requirements. Product offered to ASME-SA 312/SA 312 M shall be `SEAMLESS variety only. Product offered to ASME-SA 358/SA 358 M shall be of pipes welded with filler metal only. Pipes welded without filler metal i.e. Class-4 of SA 358 are not acceptable.
PAGE NO : 5 of 16 Welded pipe fittings offered to ASME-SA 403/SA 403 M shall further meet the ASME Section V requirements. Welding consumables shall be used only after prior approval of the Purchaser. Delta Ferrite determination, as determined in accordance with ASME Section III Clause 2433 of Sub-Section NB, NC & ND shall be within 5 FN to 10 FN. Welding consumables, procedure qualification, welder qualification etc. shall be done as per ASME Section IX / ASME Section II C. 5.0 EXAMINATION PROCEDURE For class 1 and 2 pipe fittings, the examination procedure shall be as detailed in this Section. For Class 3 Pipe fittings, examination procedure shall be as per relevant material specification. All procedures shall be submitted by Supplier to Purchaser for approval. 5.1 Radiographic Examination For Welds only: In conformance with ASME Section V Article 2, ASME-SE 94, ASME-SE 142 as modified by Clause 5111 of NB, NC & ND for Class 1, Class 2 and Class 3 pipe fittings respectively and NPCIL s specification no. PP-E-1212. 5.2 Ultrasonic Examination a) Each pipe fitting (which includes flanges also) and piping component shall be ultrasonically examined completely to cover its entire volume as per Section-V, Article-5 and ASME Section III NB 2552 (b). b) If it is not possible to cover the entire volume in the finished form, the starting stock or semi finished material, shaped nearest to the final form shall be ultrasonically examined completely and subsequently the finished product shall be ultrasonically examined to the maximum extent possible. For this proposal, NPCIL approval shall be obtained. c) Plates, pipes and forged bars used for making the pipe fittings shall be ultrasonically examined as under. For Plates : All plates 51 mm nominal thickness and less used for pipe fittings shall be examined by the angle beam ultrasonic method in accordance with ASME NB-2532-2.
PAGE NO : 6 of 16 For Pipes : Pipes used for fittings shall be examined in accordance with Article 5 of ASME Section V and NB-2552 (b). d) The ultrasonic examination acceptance standards for the starting stock or semifinished material shall be same as called for the corresponding finished product thicknesses and if any other relaxed acceptance standard is necessitated, it shall be subjected to prior approval of Purchaser. 5.3 Liquid Penetrant Examination In conformance with ASME Section V, Article 6; which is generally in accordance with ASME-SE-165 `Method for liquid penetrant inspection and NPCIL s specification no. PP-E-1209. The penetrant material shall be analysed for sulphur content and total halogens. The sulphur content and total halogens shall not each exceed 25 ppm. Inspection procedure and reagents used shall be subject to approval of the Purchaser. 5.4 Delta Ferrite Examination Delta Ferrite No. (FN) to be determined in accordance with Clause 2433 of ASME NB, NC & ND for weld metal analysis. 5.5 Intergranular Corrosion Test In conformance with ASTM-A 262, Practice A/E. 5.6 Ultrasonic Thickness Gauging In addition to thickness measurement by conventional methods ultrasonic thickness gauging shall be carried out (Ingrid pattern) on pipe fitting from each lot on random basis. For elbows the extent of examination shall be minimum 10% and for other fittings it shall be minimum 2%. If results are found to be unacceptable, the thickness gauging shall be extended on 100% of fittings. 6.0 ACCEPTANCE STANDARDS The acceptance standards shall be as detailed in this section as well as per relevant material specification whichever is more stringent. 6.1 For Radiographic Examination
PAGE NO : 7 of 16 Pipe Fittings of welded construction : Welds that are shown by radiography to have any of the following types of discontinuities are unacceptable as per Clause 2553(c) of ASME NB, NC & ND for Class 1 and Class 2, Class 3 pipe fittings. i) Any type of cracks or zone of incomplete fusion or penetration. ii) Any other elongated indication which has a length greater than (a) 6 mm for T upto 19 mm inclusive, (b) 1/3 T for T 19 mm to 57 mm inclusive. (c) 19 mm for T over 57 mm where T is the thickness of the thinner portion of weld. iii) Any group of aligned indications having an aggregate length greater than T in a length of 12 T, unless the minimum distance between successive indications is 6 L where L is the length of the longest imperfection in the group and T is the thickness of the thinner portion of weld. iv) Rounded indications in excesses of that shown as acceptable in Appendix VI. 6.2 For Ultrasonic Examination a) Pipes used in Manufacturing of Fittings Materials with defects that produce indications in excess of indications produced by the standard defects in the reference specimen are unacceptable as per ASME NB 2552. b) For Plates used in the Manufacturing of Fittings : Material which shows one or more imperfections which produce indications exceeding in amplitude the indication from the calibrated notch is unacceptable unless additional exploration by straight beam method shows the imperfections are laminar in nature and are acceptable in accordance with ASME Section III NB 2532.1 (b). c) For Forgings, Bars used in the Manufacturing of Fittings Material which shows one or more reflectors which produce indications exceeding in amplitude the indication from the appropriate calibration notches as per ASME Section III NB-2542. 6.3 For Liquid Penetrant Examination Following relevant indications are not acceptable as per Clause 2546.3 of ASME Section III NB, NC & ND.
PAGE NO : 8 of 16 a) Any linear indication greater than 1.6 mm long for materials less than 16 mm thick, greater than 3.2 mm long for materials from 16 mm thick upto 51 mm thick and 4.8 mm long for material 51 mm thick and greater. b) Rounded indication with dimensions greater than 3.2 mm for thickness less than 16 mm and greater than 4.8 mm for thickness 16 mm and greater. c) Four or more relevant indications in a line separated by 1.6 mm or less edge to edge. d) Ten or more relevant indications in any 3871 mm 2 of area whose major dimension is no more than 152 mm with dimensions taken in the most unfavorable location in relative to the indication being evaluated. 6.4 For Delta Ferrite Examination Delta Ferrite No. FN, shall be between 5 FN to 10 FN for weld metal analysis. 6.5 For Intergranular Corrosion Test As per ASTM A 262 Practice A/E. 7.0 REPAIR OF PIPE FITTINGS 7.1 Repair by Machining or Grinding All defects revealed during non destructive examination in the base material or in the weld metal may be removed by grinding or machining. Provided that the following requirements are met. a) The depression after defect elimination shall be blended uniformly into the surrounding surfaces. b) After defect elimination the area shall be re-examined by the method which originally disclosed the defect to assure that the defect has been removed. c) If the elimination of the defect should not reduce the wall thickness of the pipe below 87.5 present of nominal wall thickness. 7.2 Repair by Welding If the elimination of the defect reduces the wall thickness below the minimum specified wall thickness, then the pipes fittings may be repaired by welding with
PAGE NO : 9 of 16 prior approval of Purchaser. The depth of the repair cavity does not exceed 1/3 the nominal wall thickness of pipe fittings and the following requirements are met as per Clause 2539 of ASME NB, NC and ND. a) The defect shall be removed by suitable mechanical or thermal cutting or gauging methods and the cavity prepared for repair. b) The welding procedure and welders or welding operators shall be qualified in accordance with Clause 4000 of ASME NB, NC and ND and Sec. IX. c) After repair, the surface shall be uniformly blended into surrounding surface. d) The repaired area shall be examined by the liquid penetrant method. In addition when the depth of the repair cavity exceeds 10 mm or 10 percent of the wall thickness whichever is smaller, the repair weld shall be radiographed after repair. e) A report shall be made to the Purchaser describing the extent and location of each repair. 8.0 QUALITY CONTROL (QC) AND QUALITY ASSURANCE (QA) 8.1 All QC and QA procedures shall confirm to ASME Section III, Div.1, Subsection NCA-3800. 8.2 Quality Assurance Plan (QAP) shall be in line with that given in Appendix-A and Appendix-B for Seamless and Welded Fittings respectively and same shall be submitted for Purchaser s approval. 9.0 CLEANING All inside and outside surfaces shall be degreased and then flushed with clean water. The degreasing agent shall not contain halogens. Final cleaning shall be performed with a hot water wash using a detergent followed by a hot water rinse. The fittings shall be cleaned/pickled free from scale and shall be passivated. For pickling and passivating. it is recommended to use nitric acid. In case, hydrofluoric acid is required to be used, specific approval of NPCIL shall be required. 10.0 CERTIFICATION & IDENTIFICATION Heat Nos. and Heat Code should be marked to facilitate traceability of reports all tests and examination performed on the material.
PAGE NO : 10 of 16 Each fitting shall be marked in accordance with the appropriate ASME Specification and MSS-SP-25. The marking shall be imprinted by electric etching or other approved and permanent method of identification. Metal stamps shall not be used. Paints if used shall be free from halogens and sulphur. In addition to the above, each pipe fitting shall be painted as below : Class 1 : Blue Stripe A continuous stripe on major dimension Class 2 : Red Stripe but not extending over the machined Class 3 : Grey Stripe end preparation. 11.0 SHIPMENT The supplier shall be responsible for preparing, preserving and packing the materials supplied to this specification to protect them against corrosion and damage of any kind during shipment to the destination and also during storage at Site. All pipe fittings shall be clean and dry and both ends shall be blanked, plugged, capped or otherwise suitably sealed to prevent the ingress of moisture and particulate matter. All boxes shall be designed to include adequate cushioning, bracing etc. with provisions of lifting. The package shall be clearly and legibly marked with following information. Purchase Order No.. Brief Description of the Content. The boxes shall contain a packing slip and a copy of the authorization in form of a shipping release from Purchaser s quality surveillance representative and one copy of each test certificate. The material manufacturer shall provide a certified material test report. The certified material test report shall include the actual test results of all required chemical analysis, mechanical tests etc. Report shall also include the special requirements which have been met.
PAGE NO : 11 of 16 TABLE-1 ADDITIONAL REQUIREMENTS FOR FITTINGS OF SEAMLESS CONSTRUCTION Class Class-1 Ultrasonic Examination 100% on finished product over entire volume, (100% on the pipe/fogings used for making fittings) * Liquid Penetrant Examination 100 % external and all accessible internal surfaces Class-2 Not required 100 % on all external and accessible Intergranular Corrosion Test On one sample per lot + On one sample per lot + internal surfaces Class-3 Not required Not required On one sample per lot + Product Analysis On one sample from each size of each heat treatment batch On one sample from each size of each heat treatment batch. On one sample from each size of each heat treatment batch. * Refer clause no.5.2 of this specification.
PAGE NO : 12 of 16 TABLE-2 ADDITIONAL REQUIREMENTS FOR FITTINGS MADE BY WELDING OR OUT OF PIPES WELDED WITH FILLER METAL Class Class-1 Ultrasonic Examination 100% on finished product over entire volume (100% on plate/pipe used for making pipe fittings). * Radiographic Examination 100% on weld seam of welded pipe used in making of fitting and on welded joints of the fittings Class-2 Not required 100 % on weld seam of welded pipe used in making of fitting and on welded joints of the fittings Class-3 Not required Spot Radiography on weld seam Liquid Penetrant Examination 100 % on root and final pass and in addition 100% on all external surfaces and all accessible internal surfaces. 100% on root and final pass and in addition 100% on all external surfaces and all accessible internal surfaces. 100% on root and final pass Intergranular Corrosion Test On one sample per lot + On one sample per lot + On one sample per lot + Product Analysis One sample from each size of each heat and one sample from each lot no. of welding material of the fittings. One sample on 10% or max. 10 samples from each heat (max. no. of sizes to be covered) Required Delta Ferritic Determination Test One sample per production batch One sample per production batch One sample per production batch. + A lot shall consists of all fittings of the same type, size and wall thickness manufactured from one heat of material, heat treated either in a continuous or batch type furnace controlling within a range of 28ºC. * Refer clause no.5.2 of this specification.
PAGE NO : 13 of 16 APPENDIX A: STANDARD QUALITY ASSURANCE PLAN FOR SEAMLESS S.S. PIPE FITTINGS Sl. No OPERATION NPC S INSPECTION SAMPLE INSPECTION A B C 1. Heat Analysis One sample per raw Checking of manufacturer s test material size per heat certificates. 2. Ultrasonic test on Only when UTE on final Prior approval is required. starting stock/pipe product is not feasible. Witness the operation. 3. Heat Treatment All pipe fittings Heat Treatment Chart etc. 4. Product Analysis As per material Checking of test certificates. specification and Table-1. 5. Mechanical tests i.e. One sample from each size Witness the test operation. yield strength, % of fitting per lot. elongation, UTS, Hardness etc. 6. Intergranular Corrosion Test As per Table-1 As per ASTM A 262 Practice A/E. 7. Checking for seamless construction One sample for each size per heat Macro etch test. 8. Ultrasonic Test All class 1 pipe fittings shall As per Clause 5.2 of this be tested for transverse and specification and table-1. longitudinal direction 9. Liquid Penetrant Test LPE on external surface and accessible internal surface and repaired area As per Clause 5.3 of this specification. 10. Pickling and passivation Each pipe fitting. As per clause 9.0 of this specification. 11. Visual Inspection Test 10% random for each size Random checking of inside and outside diameter of pipe fittings. 12. Burst Test One sample as per code. For qualification of non-standard and special pipe fittings. 13. Dimensional Check Each pipe fitting shall be checked. 14. Ultrasonic thick gauging Thickness gauging in grid (For Class-1) pattern 15. Marking and colour Each fittings shall be coding. marked 16. Checking of test All certificates must be certificates checked 17. Packing All fittings shall be suitably packed and ends protected 18. Issue of third party inspection certificate and shipping release note A = Checking of Test Report B = Witnessing of Operation C = Hold Point Witness the operation. Witness the test operation at random. Random checking Checking Checking
PAGE NO : 14 of 16 APPENDIX B: STANDARD QUALITY ASSURANCE PLAN FOR WELDED S.S. PIPE FITTINGS. Sl. No. OPERATION NPC S INSPECTION SAMPLE A B C 1. Heat Analysis One sample per raw material size per heat 2. Ultrasonic test on starting stock/pipe Only when UTE on final product is not feasible. 3. Welders Qualification, Procedure Qualification, Consumable Qualification ASME II C 4. Liquid Penetrant Test on reworked areas/ weld joints. INSPECTION Checking of manufacturer s test certificates. As per Clause 5.2 of this specification. Prior approval is required witness the operation. As per ASME Section IX As per ASME Section IX, Consumable qualification is required for class-1 only. 100% on root and final pass of pipe weld / 100% on repaired area. As per Clause 5.3 of this specification. 5. Radiographic Test As per class 1 requirement of As per Clause 5.1 of this Table 2 of this specification specification. 6. Heat Treatment Each Pipe Fitting Checking of time temperature chart etc. 7. Product Analysis Table-2 requirements. Checking of manufacturer s test certificates. 8. Mechanical Tests YS, UTS, One sample from each size per As per material specification % Elongation, hardness heat Tensite specimens shall include weld and be prepared so that weld is at the mid length of specimen. 9. Delta Ferrite analysis for weld. Table-2 requirements. As per Table-2 requirements. 10. Intergranular Corrosion Test One sample from each size per heat per HT batch As per ASTM A 262 Practice A/E. 11. Ultrasonic Test Each fitting in transvers and Witness the test operation. longitudinal direction 12. Repair of defects in weld As per clause 7.0 of this As per ASME Code. specification. 13. Burst Test One sample as per code. For qualification of non-standard and special pipe fittings. 14. Dimensional check. Each pipe fitting shall be checked Witness the test operation 15. Ultrasonic thickness gauging Thickness gauging in grid Witness the test operation at (For class-1) pattern random 16. Visual Inspection Test 10% random for each size Random checking of inside and outside diameter of pipes fittings. Mill scale, degreased condition and dryness. 17. Pickling & Passivation Each Pipe Fitting As per clause 9 of this specification. 18. Marking & color coding Each pipe shall be marked Random checking 19. Checking of test certificates All certificates must be checked 20. Packing All pipes shall be suitably packed and ends protected. 21. Issue of third party inspection certificate and shipping release note A = Checking of Test Report B = Witnessing of Operation C = Hold Point Checking Checking
PAGE NO : 15 of 16 Notes:- 1. All the above operations are applicable for Class-1 pipe fittings. For Class-2 and 3 pipe fittings, the extent of operations shall be as indicated in Table-1/Table-2. 2. The lot number, heat number, coil number, mill test certificate number and its quantity shall be identified at raw material stage for ladle analysis, check test analysis and for product analysis. Random samples for various testing as required by QAP and code / material specification shall be drawn by QA representative and stamped. 3. Original test certificate of raw materials shall be required for review at the time of First Stage Inspection. 4. Manufacturer should use starting stock of pipe of sufficiently higher thickness for making pipe fittings to meet thickness reduction during process of bending, forming, scale removal, grinding for removal of surface defects if found during visual, LP/UTE marking, etc. Manufacturer shall satisfy this aspect to the purchaser s representative before taking up the work. 5. The material test laboratory shall be approved by NPCIL. 6. The heat treatment furnaces shall be in good condition and shall have temperature recorder and checked for calibration by NPCIL QA / Third party QA and the related certificate shall be submitted. The validity of calibration shall not be more than 6 months. The agency for heat treatment shall be approved by NPCIL. 7. The loading and unloading of items in the furnace may be witnessed by NPCIL QA / Third party representative. Heat treatment chart shall be submitted for review. 8. All items shall be identified to avoid mixing and proper identification during inspection and examination. 9. Vendor shall carry out 100 % dimensional check on all pipe fittings. 10. All items shall be visually examined for any imperfections and defects by vendor. 11. All NDE examinations (UTE, LPE, Eddy current testing, radiography, etc.) shall be carried out as per NPCIL approved procedures. The selection of appropriate technique(s) / method(s) shall be approved by NPCIL. Work shall be taken up after approval of procedures. 12. NPCIL QA representative / Third party shall witness 100 % UT examination and 100 % liquid penetrant examination 13. On removal of surface defects after LPE (particularly on class-i components) thickness checking shall be carried out by ultrasonic gauging. The UT instrument shall have reference master thickness gauge of required contour and capable of measuring the least count accuracy as required.
PAGE NO : 16 of 16 14. Suitable Go - NO GO gauges and fixtures may be used for dimensional inspection. Threads shall be examined by plug and ring gauges. These gauges shall have proper certification for accuracy. 15. Material traceability report (indicating material, size, item description, lot no., heat no., NDE report nos., check test certificate, vendor s final certificate no., etc.) shall be submitted. 16. Colour coding, bin card and proper tagging along with entry in proper registers shall be maintained to identify the location of material at any point during manufacturing and to avoid mixing of materials. 17. All items shall be stamped by vendor s name / monogram apart from item description, size, serial no., class, material code, rating, grade, etc. and meeting MSS-SP-25 and NPCIL specification. The fittings confirming to NPCIL specification shall be colour coded as mentioned in specification. 18. The history docket containing all test certificates, inspection reports, approved procedures, QAPs along with shipping release shall be submitted in properly bound document along with soft copy on CD. 19. In case, manufacturer intends to use On line UTE or eddy current examination or hydro test facility, the required system details shall be submitted for approval for on line witnessing and extent of witnessing. 20. Calibrated instruments shall be used for inspection, examination and testing. 21. Non destructive examinations shall be carried out by personnel qualified to level-1 of ASNT/ISNT and evaluated by ASNT/ ISNT level-ii. 22. The portion at the end of pipe/pipe fitting which is not examined by Ultrasonic Examination is to be discarded. 23. The visual examination and dimensional check shall cover outer diameter, wall thickness, workmanship, root face, end beveling, end squareness, outer and inner surface finish, out of roundness, straightness, dents on inside / outside surfaces, length, weight, marking, color coding, stamping, stenciling, processing / rolling marks on internal surface, etc. 24. After repair by grinding on parent material up to minimum wall thickness, the repaired area should be blended smoothly to the surrounding surface. 25. Check and ensure consistency and repeatability of detection in ultrasonic examination. 26. The drawing for all non-standard pipe fittings (like branched outlet fittings, lateral tees, etc for which the dimensions are not given in ANSI standards) shall be submitted for NPCIL approval. 27. QA representative shall stamp the inspected items. 28. Vendor shall submit guarantee certificate.